Dodge - Ram 2500 4wd - Workshop Manual - 1999 - 1999

Factory Workshop Manual Make Dodge Model Ram 2500 4wd Engine and year Truck L6-5.9L DSL Turbo VIN 6 (1999) Please navigate through the PDF using the options provided by OnlyManuals.com on the sidebar. This manual was submitted by Anonymous Date 1st January 2018 Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Antitheft Relay > Component Information > Locations 8w-10-2 Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Antitheft Relay > Component Information > Diagrams > Diagram Information and Instructions Antitheft Relay: Diagram Information and Instructions Introduction General Information (Part 1 Of 2) Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Antitheft Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 9 General Information (Part 2 Of 2) Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Function Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Antitheft Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 10 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Antitheft Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 11 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Antitheft Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 12 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Antitheft Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 13 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Antitheft Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 14 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Antitheft Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15 Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Antitheft Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 16 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Antitheft Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 17 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Antitheft Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 18 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Antitheft Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 19 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Antitheft Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 20 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Terminal/Connector Repair-Thomas and Betts Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Antitheft Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 21 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector. Removing Wire Terminal 4. Insert the probe end of Special Tool 6934 into the back of the connector cavity. 5. Grasp the wire and Special Tool 6934 and slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal. 7. Install the wire and terminal in the connector. Fully seat the terminal in the connector. Single Lock Tab 8. Push in the single lock tab on the side of the connector. Wiring Repair Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Antitheft Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 22 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Antitheft Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 23 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Antitheft Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 24 Antitheft Relay: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Antitheft Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 25 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Antitheft Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 26 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Antitheft Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 27 Antitheft Relay: Connector Views Power Distribution Center (PDC) Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Antitheft Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 28 Security Relay Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Radio/Stereo Noise Filter Relay > Component Information > Description and Operation Radio/Stereo Noise Filter Relay: Description and Operation FILTER, CHOKE, AND SPEAKER RELAY DESCRIPTION Models equipped with the Infinity premium speaker package have a filter, choke, and speaker relay unit. The filter, choke, and speaker relay unit is mounted to the lower instrument panel center brace, inboard of the Central Timer Module (CTM) and directly above the 16-way data link connector. The filter, choke, and speaker relay unit can be accessed for service without instrument panel disassembly or removal. The filter, choke, and speaker relay unit should be checked if there is no sound output noted from the speakers. The filter, choke, and speaker relay unit cannot be repaired or adjusted and, if faulty or damaged, the unit must be replaced. OPERATION The filter, choke, and speaker relay unit is used to control the supply of fused battery current to the front door speaker-mounted dual amplifiers. The speaker relay is energized by a fused 12 volt output from the radio receiver whenever the radio is turned on. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Radio/Stereo Noise Filter Relay > Component Information > Description and Operation > Page 32 Radio/Stereo Noise Filter Relay: Testing and Inspection The filter, choke and speaker relay is used to switch power to the individual speaker amplifiers used with the Infinity premium speaker package. The choke and relay are serviced only as a unit. If all of the speakers lack bass or low frequency response, the filter, choke and speaker relay unit should be considered suspect. However, before replacement make the following checks of the filter, choke and speaker relay circuits. 1. Check the fused B(+) fuse in the junction block. If OK, go to Step 2.If not OK, replace the faulty fuse. 2. Check for battery voltage at the fused B(+) fuse in the junction block. If OK, go to Step 3. If not OK, repair the open fused B(+) circuit to the battery as required. 3. Disconnect the instrument panel wire harness connector from the filter, choke and speaker relay unit. Check for battery voltage at the fused B(+) circuit cavity of the instrument panel wire harness connector for the filter, choke and speaker relay unit. If OK, go to Step 4. If not OK, repair the open fused B(+) circuit to the junction block fuse as required. 4. Probe the ground circuit cavity of the instrument panel wire harness connector for the filter, choke and speaker relay unit. Check for continuity to a good ground. There should be continuity. If OK, go to Step 5. If not OK, repair the open ground circuit to ground as required. 5. Turn the ignition switch to the On position and turn the radio on. Check for battery voltage at the radio 12 volt output circuit cavity of the instrument panel wire harness connector for the filter, choke and speaker relay unit. If OK, go to Step 6. If not OK, repair the open radio 12 volt output circuit to the radio as required. 6. Turn the radio and ignition switches to the Off position. Reconnect the instrument panel wire harness connector to the filter, choke and speaker relay unit. Check for battery voltage at the amplified speaker (+) circuit cavity of the instrument panel wire harness connector for the filter, choke and speaker relay unit. There should be zero volts. Turn the ignition and radio switches to the On position. There should now be battery voltage. If OK, repair the open amplified speaker (+) circuits to the speaker-mounted amplifiers as required. If not OK, replace the faulty filter, choke and speaker relay unit. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Radio/Stereo Noise Filter Relay > Component Information > Description and Operation > Page 33 Radio/Stereo Noise Filter Relay: Service and Repair WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIR BAGS AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. REMOVAL 1. Disconnect and isolate the battery negative cable. Filter, Choke And Speaker Relay Remove/Install 2. Reach under the driver side of the instrument panel near the 16-way data link connector and inboard of the ash receiver to access the filter, choke and speaker relay. 3. Disconnect the instrument panel wire harness connector from the filter, choke and speaker relay wire harness connector. 4. Remove the two screws that secure the filter, choke, and speaker relay mounting bracket to the instrument panel center brace. 5. Remove the filter, choke, and speaker relay unit from under the instrument panel. INSTALLATION 1. Position the filter, choke, and speaker relay unit under the instrument panel. 2. Install and tighten the two screws that secure the filter, choke, and speaker relay mounting bracket to the instrument panel center brace. Tighten the screws to 2.7 Nm (24 in lbs). 3. Reconnect the instrument panel wire harness connector to the filter, choke and speaker relay wire harness connector. 4. Reconnect the battery negative cable. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Specifications Electronic Brake Control Module: Specifications WITH RWAL ANTILOCK BRAKES: Mounting Screws .............................................................................................................................................................. 2.5 - 3.5 Nm (22 - 31 inch lbs.) WITH 4-WHEEL ANTILOCK BRAKES: Mounting Screws ................................................................................................................................. ................................ 4 - 4.7 Nm (36 - 42 inch lbs.) Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Control Modules, PDC, and Relays Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Control Modules, PDC, and Relays > Page 40 Electronic Brake Control Module: Locations EBC 2 Controller Antilock Brakes (CAB) EBC 2 Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Control Modules, PDC, and Relays > Page 41 Electronic Brake Control Module: Locations EBC 325 Controller Antilock Brakes (CAB) EBC 32 5 EBC-325 Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Diagrams > Connector Plug C1 Electronic Brake Control Module: Diagrams Connector Plug C1 Connector Pin Identification Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Diagrams > Connector Plug C1 > Page 44 Electronic Brake Control Module: Diagrams Connector Plug C2 Connector Pin Identification Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Description and Operation > Controller Antilock Brake (CAB) Electronic Brake Control Module: Description and Operation Controller Antilock Brake (CAB) The controller antilock brake module is used to monitor wheel speeds and modulates (control) hydraulic pressure in each brake channel. The modulated hydraulic pressure is used to prevent wheel lock up during braking. The CAB also provides a vehicle speed signal (VSS) to the powertrain control module. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Description and Operation > Controller Antilock Brake (CAB) > Page 47 Electronic Brake Control Module: Description and Operation With Four Wheel Antilock Brakes CAB/HCU The CAB is mounted on the top of the hydraulic control unit. The CAB operates the ABS system and is separate from other vehicle electrical circuits. CAB voltage source is through the ignition switch in the RUN position. The CAB contains dual microprocessors. A logic block in each microprocessor receives identical sensor signals. These signals are processed and compared simultaneously. The CAB contains a self check program that illuminates the ABS warning light when a system fault is detected. Faults are stored in a diagnostic program memory and are accessible with the DRB scan tool. ABS faults remain in memory until cleared, or until after the vehicle is started approximately 50 times. Stored faults are not erased if the battery is disconnected. NOTE: If the CAB needs to be replaced, the rear axle type and tire revolutions per mile must be programmed into the new CAB. For axle type refer to Transmission and Drivetrain. For tire revolutions per mile refer to Steering and Suspension. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Description and Operation > Controller Antilock Brake (CAB) > Page 48 Electronic Brake Control Module: Description and Operation With Rear Wheel Antilock Brakes RWAL CAB The Controller Antilock Brakes (CAB) is a microprocessor which handles testing, monitoring and controlling the ABS brake system operation. The CAB functions are: Perform self-test diagnostics. - Monitor the RWAL brake system for proper operation. - Control the RWAL valve solenoids. NOTE: If the CAB needs to be replaced, the rear axle type and tire revolutions per mile must be programmed into the new CAB. For axle type refer to Transmission and Drivetrain. For tire revolutions per mile refer to Steering and Suspension. SYSTEM SELF-TEST When the ignition switch is turned-on the microprocessor RAM and ROM are tested. If an error occurs during the test, a DTC will be set into the RAM memory. However it is possible the DTC will not be stored in memory if the error has occurred in the RAM module were the DTC's are stored. Also it is possible a DTC may not be stored if the error has occurred in the ROM which signals the RAM to store the DTC. CAB INPUTS The CAB continuously monitors the speed of the differential ring gear by monitoring signals generated by the rear wheel speed sensor. The CAB determines a wheel locking tendency when it recognizes the ring gear decelerating too rapidly. The CAB monitors the following inputs to determine when a wheel locking tendency may exists: - Rear Wheel Speed Sensor - Brake Lamp Switch - Brake Warning Lamp Switch - Reset Switch - 4WD Switch (If equipped) CAB OUTPUTS The CAB controls the following outputs for antilock braking and brake warning information: RWAL Valve - ABS Warning Lamp - Brake Warning Lamp Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Service and Repair > Antilock Control Assembly Replacement Electronic Brake Control Module: Service and Repair Antilock Control Assembly Replacement NOTE: If the antilock control assembly needs to be replaced, the rear axle type and tire revolutions per mile must be programmed into the new CAB. For axle type refer to Transmission and Drivetrain. For tire revolutions per mile refer to Steering and Suspension. REMOVAL 1. Disconnect battery negative cable. 2. Push the harness connector locks to release the locks, then remove the connectors from the CAB. Brake Lines 3. Disconnect brake lines from HCU. 4. Remove the two mounting bolts on either side of the assembly which attach the assembly to the mounting bracket. 5. Tilt the assembly upward were the brake lines attach and remove the assembly from the mounting bracket. INSTALLATION 1. Install the assembly into the mounting bracket. 2. Install the mounting bolts and tighten to 12 Nm (102 inch lbs.). 3. Connect the CAB harnesses. 4. Connect the brake lines to the HCU. Tighten brake line fittings to 19 - 23 Nm (170 - 200 inch lbs.). 5. Connect battery. 6. Bleed brake system. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Service and Repair > Antilock Control Assembly Replacement > Page 51 Electronic Brake Control Module: Service and Repair Controller Antilock Brake (CAB) Replacement Four Wheel Antilock Brake System NOTE: If the CAB needs to be replaced, the rear axle type and tire revolutions per mile must be programmed into the new CAB. For axle type refer to Transmission and Drivetrain. For tire revolutions per mile refer to Steering and Suspension. REMOVAL 1. Disconnect battery negative cable. Harness Connector Locks 2. Push the harness connector locks to release the locks, then remove the connectors from the CAB. Pump Motor Connector 3. Disconnect the pump motor connector. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Service and Repair > Antilock Control Assembly Replacement > Page 52 Controller Mounting Screws 4. Remove screws attaching CAB to the HCU. 5. Remove the CAB. INSTALLATION 1. Place the CAB onto the HCU. NOTE: Insure the CAB seal is in position before installation. 2. Install the mounting screws and tighten to 4 - 4.7 Nm (36 - 42 inch lbs.). 3. Connect the pump motor harness. 4. Connect the harnesses to the CAB and lock the connectors. 5. Connect battery. Rear Wheel Antilock Brake System NOTE: If the CAB needs to be replaced, the rear axle type and tire revolutions per mile must be programmed into the new CAB. For axle type refer to Transmission and Drivetrain. For tire revolutions per mile refer to Steering and Suspension. REMOVAL CAB Harness Connections 1. Pull up on the CAB harness connector lock release and remove the connector from the controller. 2. Remove the RWAL valve harness connector from the controller. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Service and Repair > Antilock Control Assembly Replacement > Page 53 CAB Mounting Screws 3. Remove the controller mounting screws, and remove the controller from the mounting bracket. INSTALLATION 1. Position the controller on the bracket and install the mounting screws. Tighten the screws to 2.5 3.5 Nm (22 - 31 inch lbs.). 2. Install the RWAL valve harness connector into the controller. 3. Install the CAB harness connector into the controller and push down on the connector lock. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Component Locations Blower Motor Relay: Component Locations 8w-10-2 The blower motor relay is located in the PDC in the engine compartment. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Component Locations > Page 59 Blower Motor Relay: Connector Locations Power Distribution Center (PDC) Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Component Locations > Page 60 Blower Motor Relay Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Page 61 Blower Motor Relay: Description and Operation SYSTEM OPERATION The blower motor relay is an International Standards Organization (ISO)-type relay. The relay is an electromechanical device that switches battery current from a fuse in the Power Distribution Center (PDC) directly to the blower motor. The relay is energized when the relay coil is provided a voltage signal by the ignition switch. This arrangement reduces the amount of battery current that must flow through the ignition switch. The blower motor relay control circuit is protected by a fuse located in the junction block. When the relay is de-energized, the blower motor receives no battery current. See Blower Motor Relay in the Diagnosis and Testing for more information. The blower motor relay is located in the PDC in the engine compartment. Refer to the PDC label for blower motor relay identification and location. The blower motor relay cannot be repaired and, if faulty or damaged, it must be replaced. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Page 62 Blower Motor Relay: Testing and Inspection Relay Test Blower Motor Relay The blower motor relay is located in the Power Distribution Center (PDC). Remove the blower motor relay from the PDC to perform the following tests: 1. A relay in the de-energized position should have continuity between terminals 87A and 30, and no continuity between terminals 87 and 30. If OK, go to Step 2. If not OK, replace the faulty relay. 2. Resistance between terminals 85 and 86 (electromagnet) should be 75 ± 5 ohms. If OK, go to Step 3. If not OK, replace the faulty relay. 3. Connect a battery to terminals 85 and 86. There should now be continuity between terminals 30 and 87, and no continuity between terminals 87A and 30. If OK, see Relay Circuit Test in the Diagnosis and Testing. If not OK, replace the faulty relay. Relay Circuit Test 1. The relay common feed terminal cavity (30) is connected to fused battery feed directly from a fuse in the Power Distribution Center (PDC), and should be hot at all times. Check for battery voltage at the PDC cavity for relay terminal 30. If OK, go to Step 2. If not OK, repair the open circuit to the PDC fuse as required. 2. The relay normally closed terminal cavity (87A) is not used for this application. Go to Step 3. 3. The relay normally open terminal cavity (87) is connected to the blower motor. When the relay is energized, terminal 87 is connected to terminal 30 and provides full battery current to the blower motor feed circuit. There should be continuity between the PDC cavity for terminal 87 and the blower motor relay output circuit cavity of the blower motor wire harness connector at all times. If OK, go to Step 4. If not OK, repair the open circuit to the blower motor as required. 4. The coil battery terminal cavity (86) is connected to the ignition switch. When the ignition switch is placed in the On position, fused ignition switch output is directed from a fuse in the junction block to the relay electromagnetic coil to energize the relay There should be battery voltage at the PDC cavity for relay terminal 86 with the ignition switch in the On position. If OK, go to Step 5. If not OK, repair the open circuit to the junction block fuse as required. 5. The coil ground terminal cavity (85) is connected to ground. This terminal supplies the ground for the relay electromagnetic coil. There should be continuity between the PDC cavity for relay terminal 85 and a good ground at all times. If not OK, repair the open circuit as required. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Page 63 Blower Motor Relay: Service and Repair REMOVAL AND INSTALLATION 1. Disconnect and isolate the battery negative cable. Power Distribution Center 2. Remove the cover from the Power Distribution Center (PDC). 3. Refer to the label on the PDC for blower motor relay identification and location. 4. Unplug the blower motor relay from the PDC. 5. Install the blower motor relay by aligning the relay terminals with the cavities in the PDC and pushing the relay firmly into place. 6. Install the PDC cover. 7. Connect the battery negative cable. 8. Test the relay operation. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Component Locations Compressor Clutch Relay: Component Locations 8w-10-2 Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Component Locations > Page 68 Power Distribution Center The compressor clutch relay is located in the Power Distribution Center (PDC) in the engine compartment. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Component Locations > Page 69 Compressor Clutch Relay: Connector Locations Power Distribution Center (PDC) Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Component Locations > Page 70 A/C Compressor Clutch Relay Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Description and Operation > A/C Compressor Clutch Relay Description Compressor Clutch Relay: Description and Operation A/C Compressor Clutch Relay Description SYSTEM OPERATION The compressor clutch relay is a International Standards Organization (ISO) micro-relay. The terminal designations and functions are the same as a conventional ISO relay. However, the micro-relay terminal orientation (footprint) is different, the current capacity is lower, and the relay case dimensions are smaller than those of the conventional ISO relay The compressor clutch relay is a electromechanical device that switches battery current to the compressor clutch coil when the Powertrain Control Module (PCM) grounds the coil side of the relay. The PCM responds to inputs from the heater-A/C mode control switch, the low pressure cycling clutch switch, and the high pressure cut-off switch. See Compressor Clutch Relay in the Diagnosis and Testing for more information. The compressor clutch relay is located in the Power Distribution Center (PDC) in the engine compartment. Refer to the PDC label for relay identification and location. The compressor clutch relay cannot be repaired and, if faulty or damaged, it must be replaced. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Description and Operation > A/C Compressor Clutch Relay Description > Page 73 Compressor Clutch Relay: Description and Operation A/C Compressor Clutch Relay-PCM Output AIR CONDITIONING (A/C) CLUTCH RELAY - PCM OUTPUT Power Distribution Center (PDC) The A/C relay is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. The powertrain control module (PCM) activates the A/C compressor through the A/C clutch relay. The PCM regulates A/C compressor operation by switching the ground circuit for the A/C clutch relay on and off. When the PCM receives a request for A/C, it will adjust idle air control (IAC) motor position. This is done to increase idle speed. The PCM will then activate the A/C clutch through the A/C clutch relay. The PCM adjusts idle air control (IAC) stepper motor position to compensate for increased engine load from the A/C compressor. By switching the ground path for the relay on and oft, the PCM is able to cycle the A/C compressor clutch. This is based on changes in engine operating conditions. If, during A/C operation, the PCM senses low idle speeds or a wide open throttle condition, it will de-energize the relay. This prevents A/C clutch engagement. The relay will remain de-energized until the idle speed increases or the wide open throttle condition exceeds 15 seconds or no longer exists. The PCM will also de-energize the relay if coolant temperature exceeds 125 °C (257 °F) or low or high system pressure exists. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Description and Operation > Page 74 Compressor Clutch Relay: Testing and Inspection Relay Test Compressor Clutch Relay The compressor clutch relay is located in the Power Distribution Center (PDC). Refer to the PDC label for relay identification and location. Remove the relay from the PDC to perform the following tests: 1. A relay in the de-energized position should have continuity between terminals 87A and 30, and no continuity between terminals 87 and 30. If OK, go to Step 2. If not OK, replace the faulty relay. 2. Resistance between terminals 85 and 86 (electromagnet) should be 75 ± 5 ohms. If OK, go to Step 3. If not OK, replace the faulty relay 3. Connect a battery to terminals 85 and 86. There should now be continuity between terminals 30 and 87, and no continuity between terminals 87A and 30. If OK, see Relay Circuit Test in the Diagnosis and Testing. If not OK, replace the faulty relay Relay Circuit Test 1. The relay common feed terminal cavity (30) is connected to fused battery feed. There should be battery voltage at the cavity for relay terminal 30 at all times. If OK, go to Step 2. If not OK, repair the open circuit to the fuse in the PDC as required. 2. The relay normally closed terminal (87A) is not used in this application. Go to Step 3. 3. The relay normally open terminal cavity (87) is connected to the compressor clutch coil. There should be continuity between this cavity and the A/C compressor clutch relay output circuit cavity of the compressor clutch coil wire harness connector. If OK, go to Step 4. If not OK, repair the open circuit as required. 4. The relay coil battery terminal (86) is connected to the fused ignition switch output (run/start) circuit. There should be battery voltage at the cavity for relay terminal 86 with the ignition switch in the On position. If OK, go to Step 5. If not OK, repair the open circuit to the fuse in the junction block as required. 5. The coil ground terminal cavity (85) is switched to ground through the Powertrain Control Module (PCM). There should be continuity between this cavity and the A/C compressor clutch relay control circuit cavity of the PCM wire harness connector C (gray) at all times. If not OK, repair the open circuit as required. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Description and Operation > Page 75 Compressor Clutch Relay: Service and Repair REMOVAL AND INSTALLATION 1. Disconnect and isolate the battery negative cable. Power Distribution Center 2. Remove the cover from the Power Distribution Center (PDC). 3. Refer to the label on the PDC for compressor clutch relay identification and location. 4. Unplug the compressor clutch relay from the PDC. 5. Install the compressor clutch relay by aligning the relay terminals with the cavities in the PDC and pushing the relay firmly into place. 6. Install the PDC cover. 7. Connect the battery negative cable. 8. Test the relay operation. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Specifications Audible Warning Device Control Module: Specifications Tighten the two screws that secure the CTM to the mounting bracket on the inboard side of instrument panel steering column opening to 1.6 Nm (15 in lbs). Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Specifications > Page 80 Audible Warning Device Control Module: Locations Central Time Module (Base) Remove/Install Central Time Module (High-Line) Remove/Install Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions Audible Warning Device Control Module: Diagram Information and Instructions Introduction General Information (Part 1 Of 2) Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 83 General Information (Part 2 Of 2) Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Function Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 84 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 85 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 86 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 87 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 88 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 89 Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 90 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 91 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 92 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 93 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 94 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Terminal/Connector Repair-Thomas and Betts Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 95 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector. Removing Wire Terminal 4. Insert the probe end of Special Tool 6934 into the back of the connector cavity. 5. Grasp the wire and Special Tool 6934 and slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal. 7. Install the wire and terminal in the connector. Fully seat the terminal in the connector. Single Lock Tab 8. Push in the single lock tab on the side of the connector. Wiring Repair Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 96 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 97 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 98 Audible Warning Device Control Module: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 99 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 100 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 101 Audible Warning Device Control Module: Connector Views Central Timer Module C1 (Integrated Electronic Module) Central Timer Module C2 Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 102 Audible Warning Device Control Module: Electrical Diagrams Central Timer Module 8w-45-2 Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 103 8w-45-3 Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 104 8w-45-4 Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 105 8w-45-5 Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 106 8w-45-6 Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 107 8w-45-7 (IEM) Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 108 8w-45-8 (IEM) Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 109 8w-45-9 (IEM) NOTE: To view sheets referred to in these diagrams, see Complete Body and Chassis Diagrams See: Diagrams/Electrical Diagrams. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 110 Central Timer Module System Central Timer Module System Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Page 111 Audible Warning Device Control Module: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIR BAGS AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY . Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Page 112 Audible Warning Device Control Module: Description and Operation The Ram Truck utilizes a Central Timer Module (CTM). This system is available in a Base or High line configuration. The Base (IEM) configuration does not communicate on the CCD bus and will not be addressed. The CTM will handle most of the electronic timing and chime functions for the systems on the truck. For example: the halo lamp around the key cylinder is timed out after 30 seconds. This is a typical CTM function. The High line CTM provides the following features: - Remote Keyless Entry (RKE) - Chime - Courtesy Lamp controls/Illuminated Entry - Power Door Locks - Speed Sensitive Intermittent Wipers - Enhanced Accident Response - Vehicle Theft Security System (VTSS) The CTM is located on the right side of the steering column behind the kneeblocker on a metal bracket welded to the instrument panel. It contains a white 8-way and a green 14-way connector. For additional information on the Central Timer Module, refer to Powertrain Management / Computers and Control Systems / Body Control Module. See: Relays and Modules - Powertrain Management/Relays and Modules - Computers and Control Systems/Central Timer Module/Description and Operation Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Page 113 Audible Warning Device Control Module: Testing and Inspection For additional testing and inspection information please refer to Powertrain Management/Computers and Control Systems/ See: Relays and Modules - Powertrain Management/Relays and Modules - Computers and Control Systems/Central Timer Module NOTE: The following tests may not prove conclusive in the diagnosis of the high-line version of the Central Timer Module (CTM). The most reliable, efficient, and accurate means to diagnose the high-line CTM requires the use of a DRB scan tool and the proper Diagnostic Procedures. 1. Check the fuses in the junction block. If OK, go to Step 2.If not OK, repair the shorted circuit or component as required and replace the faulty fuse. 2. Check for battery voltage at the fuse in the junction block. If OK, go to Step 3. If not OK, repair the open circuit to the Power Distribution Center (PDC) as required. 3. Disconnect and isolate the battery negative cable. Remove the Central Timer Module (CTM) from its mounting bracket to access the CTM wire harness connectors. Refer to Central Timer Module in the Replacement of Instrument Panel Systems for the procedures. 4. Unplug the wire harness connectors from the CTM. Check the wire harness connectors and the receptacles in the CTM for loose, corroded, or damaged terminals and pins. If OK, go to Step 5. If not OK, repair as required. 5. Probe the ground circuit cavity of the 14-way CTM wire harness connector and check for continuity to a good ground. Repeat the check between the ground circuit cavity of the 18-way CTM wire harness connector and a good ground. In each case, there should be continuity. If OK, go to Step 6. If not OK, repair the open circuit(s) to ground as required. 6. Connect the battery negative cable. Check for battery voltage at the fused B(+) circuit cavity of the 14-way CTM wire harness connector. If OK, go to Step 7. If not OK, repair the open circuit to the junction block as required. 7. Probe the door lock switch output (lock) circuit cavity of the 18-way CTM wire harness connector and check for battery voltage as you actuate each power lock switch to the Lock position. If OK, go to Step 8. If not OK, repair the open circuit from either or both power lock switch(es) to the CTM as required. 8. Probe the door lock switch output (unlock) circuit cavity of the 18-way CTM wire harness connector and check for battery voltage as you actuate each power lock switch to the Unlock position. If OK, go to Step 9. If not OK, repair the open circuit from either or both power lock switch(es) to the CTM as required. 9. Disconnect and isolate the battery negative cable. Reinstall the wire harness connectors to the CTM. Connect the battery negative cable. Back-probe the door lock driver circuit cavity of the 18-way CTM wire harness connector and check for battery voltage as either power lock switch is moved to the Lock position. Repeat the test pressing the Lock button of the Remote Keyless Entry (RKE) transmitter. If OK, go to Step 10. If not OK using the power lock switch, but OK with the RKE transmitter, see Power Lock Switch in the Diagnosis and Testing. If not OK using the RKE transmitter, but OK with the power lock switch, see Remote Keyless Entry Transmitter in the Diagnosis and Testing. If not OK, with the power lock switch or the RKE transmitter, replace the faulty CTM. 10. Back-probe the door unlock driver circuit cavity of the 18-way CTM wire harness connector and check for battery voltage as the power lock switch is moved to the Unlock position. Repeat the test pressing the Unlock button of the RKE transmitter. If OK, see Power Lock Motor in the Diagnosis and Testing. If not OK using the power lock switch, but OK with the RKE transmitter, see Power Lock Switch in the Diagnosis and Testing. If not OK using the RKE transmitter, but OK with the power lock switch, see Remote Keyless Entry Transmitter in the Diagnosis and Testing. If not OK, with the power lock switch or the RKE transmitter, replace the faulty CTM. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Page 114 Audible Warning Device Control Module: Service and Repair Before replacing a high-line Central Timer Module (CTM), use a DRB scan tool to determine the current settings for the CTM programmable features. These settings should be duplicated in the replacement CTM using the DRB scan tool, before returning the vehicle to service. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIR BAGS AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the steering column opening cover from the instrument panel. Refer to Steering Column Opening Cover in the Replacement for the procedures. Central Time Module (Base) Remove/Install Central Time Module (High-Line) Remove/Install 3. Remove the two screws that secure the Central Timer Module (CTM) to the bracket on the inboard side of the instrument panel steering column opening. 4. Pull the CTM into the instrument panel steering column opening far enough to access the instrument panel wire harness connector(s). 5. Disconnect the instrument panel wire harness connector(s) (one connector for the base CTM, two connectors for high-line CTM) from the CTM connector receptacle(s). 6. Remove the CTM from the instrument panel. INSTALLATION 1. Position the CTM in the instrument panel steering column opening. 2. Reconnect the instrument panel wire harness connector(s) (one connector for the base CTM, two connectors for high-line CTM) to the CTM connector receptacle(s). 3. Position the CTM to the mounting bracket on the inboard side of the instrument panel steering column opening. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Page 115 4. Install and tighten the two screws that secure the CTM to the mounting bracket on the inboard side of instrument panel steering column opening. Tighten the screws to 1.6 Nm (15 in lbs). 5. Install the steering column opening cover onto the instrument panel. Refer to Steering Column Opening Cover in the Replacement for the procedures. 6. Reconnect the battery negative cable. NOTE: If a new high-line Central Timer Module is installed, the programmable features must be enabled and/or disabled to the customer's preferred settings. Use a DRB scan tool and the proper Diagnostic Procedures to perform these operations. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Locations Daytime Running Lamp Control Unit: Locations Daytime Running Lamp Module (DRLM) The Daytime Running Lamp Module (DRLM) is located in the engine compartment on the left fender wheelhouse. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Locations > Page 120 Daytime Running Lamp Control Unit: Description and Operation GENERAL INFORMATION The daytime running lamps are controlled by the Daytime Running Lamp Module (DRLM). The DRLM is located in the engine compartment on the left fender wheelhouse. The DRLM allows the high beam headlamps to illuminate at a reduced intensity when the engine is running with the headlamp switch OFF. The Daytime running lamps will go out when the headlamp switch is turned to the headlamps on position. The passing light feature will flash bright high beams while the daytime running lamps are activated. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Locations > Page 121 Daytime Running Lamp Control Unit: Service and Repair Daytime Running Lamp Module (DRLM) REMOVAL 1. Release hood latch an open hood. 2. Disengage wire connector from DRLM. 3. Remove screws attaching DRLM to left front inner fender panel. 4. Separate DRLM from fender. INSTALLATION 1. Position DRLM on fender. 2. Install screws attaching DRLM to left front inner fender panel. 3. Engage wire connector to DRLM. 4. Close hood. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations 8w-10-2 Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations > Page 125 Fog/Driving Lamp Relay: Diagrams Power Distribution Center (PDC) Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations > Page 126 Fog Lamp Relay Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Locations Headlamp Relay: Locations Power Distribution Center The headlamp (or security) relay is located in the Power Distribution Center (PDC), in the engine compartment. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Locations > Page 130 Headlamp Relay: Diagrams Power Distribution Center Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Locations > Page 131 Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Locations > Page 132 Headlamp Relay: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIR BAGS AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Locations > Page 133 Headlamp Relay: Description and Operation SYSTEM OPERATION The headlamp (or security) relay is a International Standards Organization (ISO) micro-relay. The terminal designations and functions are the same as a conventional ISO relay. However, the micro-relay terminal orientation (or footprint) is different, current capacity is lower, and the relay case dimensions are smaller than those of the conventional ISO relay. The headlamp relay is a electromechanical device that switches battery current to the headlamps when the high-line Central Timer Module (CTM) grounds the relay coil. See Headlamp Relay in the Diagnosis and Testing for more information. The headlamp (or security) relay is located in the Power Distribution Center (PDC), in the engine compartment. Refer to the PDC label for relay identification and location. The headlamp relay cannot be repaired and, if faulty or damaged, it must be replaced. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Locations > Page 134 Headlamp Relay: Testing and Inspection The headlamp (or security) relay and the horn relay are located in the Power Distribution Center (PDC) in the engine compartment. Each of these relays can be tested as described in the following procedure, however the circuits they are used in do vary. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIR BAGS AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Relay Terminals Remove the relay from the PDC as described to perform the following tests: 1. A relay in the de-energized position should have continuity between terminals 87A and 30, and no continuity between terminals 87 and 30. If OK, go to Step 2.If not OK, replace the faulty relay 2. Resistance between terminals 85 and 86 (electromagnet) should be 75 ± 5 ohms. If OK, go to Step 3. If not OK, replace the faulty relay. 3. Connect a battery to terminals 85 and 86. There should now be continuity between terminals 30 and 87, and no continuity between terminals 87A and 30. If OK, test the relay circuits. If not OK, replace the faulty relay. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Locations > Page 135 Headlamp Relay: Service and Repair Power Distribution Center REMOVAL AND INSTALLATION 1. Disconnect and isolate the battery negative cable. 2. Remove the cover from the Power Distribution Center (PDC). 3. Refer to the label on the PDC for headlamp (or security) relay identification and location. 4. Unplug the headlamp relay from the PDC. 5. Install the headlamp relay by aligning the relay terminals with the cavities in the PDC and pushing the relay firmly into place. 6. Install the PDC cover. 7. Connect the battery negative cable. 8. Test the relay operation. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > High Beam Relay > Component Information > Locations 8w-10-2 Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > High Beam Relay > Component Information > Locations > Page 139 High Beam Relay: Diagrams Power Distribution Center (PDC) Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > High Beam Relay > Component Information > Locations > Page 140 Quad High Beam Relay Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations Horn Relay: Locations 8w-10-2 Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 144 Power Distribution Center The horn relay is located in the Power Distribution Center (PDC) in the engine compartment. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Diagrams > Diagram Information and Instructions Horn Relay: Diagram Information and Instructions Introduction General Information (Part 1 Of 2) Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 147 General Information (Part 2 Of 2) Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Function Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 148 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 149 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 150 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 151 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 152 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 153 Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 154 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 155 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 156 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 157 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 158 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Terminal/Connector Repair-Thomas and Betts Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 159 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector. Removing Wire Terminal 4. Insert the probe end of Special Tool 6934 into the back of the connector cavity. 5. Grasp the wire and Special Tool 6934 and slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal. 7. Install the wire and terminal in the connector. Fully seat the terminal in the connector. Single Lock Tab 8. Push in the single lock tab on the side of the connector. Wiring Repair Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 160 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 161 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 162 Horn Relay: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 163 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 164 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 165 Horn Relay: Connector Views Power Distribution Center (PDC) Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 166 Horn Relay Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Diagrams > Page 167 Horn Relay: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO RESTRAINT SYSTEMS / AIRBAG SYSTEMS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY . Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Diagrams > Page 168 Horn Relay: Description and Operation DESCRIPTION The horn relay is a electromechanical device that switches battery current to the horn when the horn switch grounds the relay coil. The horn relay is located in the Power Distribution Center (PDC) in the engine compartment. If a problem is encountered with a continuously sounding horn, it can usually be quickly resolved by removing the horn relay from the PDC until further diagnosis is completed. See the fuse and relay layout label affixed to the inside surface of the PDC cover for horn relay identification and location. The horn relay is a International Standards Organization (ISO) micro-relay. Relays conforming to the ISO specifications have common physical dimensions, current capacities, terminal patterns, and terminal functions. The ISO micro-relay terminal functions are the same as a conventional ISO relay. However, the ISO micro-relay terminal pattern (or footprint) is different, the current capacity is lower, and the physical dimensions are smaller than those of the conventional ISO relay. The horn relay is located in the Power Distribution Center (PDC), in the engine compartment. Refer to the PDC label for relay identification and location. If a problem is encountered with a continuously sounding horn, it can usually be quickly resolved by removing the horn relay from the PDC until further diagnosis is completed. The horn relay cannot be repaired or adjusted and, if faulty or damaged, it must be replaced. OPERATION The ISO relay consists of an electromagnetic coil, a resistor or diode, and three (two fixed and one movable) electrical contacts. The movable (common feed) relay contact is held against one of the fixed contacts (normally dosed) by spring pressure. When the electromagnetic coil is energized, it draws the movable contact away from the normally closed fixed contact, and holds it against the other (normally open) fixed contact. When the electromagnetic coil is de-energized, spring pressure returns the movable contact to the normally closed position. The resistor or diode is connected in parallel with the electromagnetic coil in the relay, and helps to dissipate voltage spikes that are produced when the coil is de-energized. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Diagrams > Page 169 Horn Relay: Testing and Inspection Horn Relay The horn relay is located in the Power Distribution Center (PDC) behind the battery on the driver side of the engine compartment. If a problem is encountered with a continuously sounding horn, it can usually be quickly resolved by removing the horn relay from the PDC until further diagnosis is completed. See the fuse and relay layout label affixed to the inside surface of the PDC cover for horn relay identification and location. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIR BAGS AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. For additional testing and inspection information please refer to Powertrain Management/Computers and Control Systems/ See: Relays and Modules - Powertrain Management/Relays and Modules - Computers and Control Systems/Central Timer Module 1. Remove the horn relay from the PDC. Refer to Horn Relay in the Replacement for the procedures. 2. A relay in the de-energized position should have continuity between terminals 87A and 30, and no continuity between terminals 87 and 30. If OK, go to Step 3. If not OK, replace the faulty relay. 3. Resistance between terminals 85 and 86 (electromagnet) should be 75 ± 5 ohms. If OK, go to Step 4. If not OK, replace the faulty relay 4. Connect a battery to terminals 85 and 86. There should now be continuity between terminals 30 and 87, and no continuity between terminals 87A and 30. If OK, perform the Relay Circuit Test that follows. If not OK, replace the faulty relay Relay Circuit Test 1. The relay common feed terminal cavity (30) is connected to battery voltage and should be hot at all times. If OK, go to Step 2.If not OK, repair the open circuit to the fuse in the PDC as required. 2. The relay normally closed terminal (87A) is connected to terminal 30 in the de-energized position, but is not used for this application. Go to Step 3. 3. The relay normally open terminal (87) is connected to the common feed terminal (30) in the energized position. This terminal supplies battery voltage to the horn(s). There should be continuity between the cavity for relay terminal 87 and the horn relay output circuit cavity of each horn wire harness connector at all times. If OK, go to Step 4. If not OK, repair the open circuit to the horn(s) as required. 4. The coil battery terminal (86) is connected to the electromagnet in the relay It is connected to battery voltage and should be hot at all times. Check for battery voltage at the cavity for relay terminal 86. If OK, go to Step 5. If not OK, repair the open circuit to the fuse in the PDC as required. 5. The coil ground terminal (85) is connected to the electromagnet in the relay. It is grounded through the horn switch when the horn switch is depressed. On vehicles equipped with the Vehicle Theft Security System (VTSS), the horn relay coil ground terminal can also be grounded by the Central Timer Module (CTM) in response to certain inputs related to the VTSS or Remote Keyless Entry (RKE) system. Check for continuity to ground at the cavity for relay terminal 85. There should be continuity with the horn switch depressed, and no continuity with the horn switch released. If not OK, refer to Horn Switch in the Diagnosis and Testing. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Diagrams > Page 170 Horn Relay: Service and Repair Power Distribution Center REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the cover from the Power Distribution Center (PDC). 3. See the fuse and relay layout label affixed to the underside of the PDC cover for horn relay identification and location. 4. Remove the horn relay from the PDC. INSTALLATION 1. See the fuse and relay layout label affixed to the underside of the PDC cover for the proper horn relay location. 2. Position the horn relay in the proper receptacle in the PDC. 3. Align the horn relay terminals with the terminal cavities in the PDC receptacle. 4. Push down firmly on the horn relay until the terminals are fully seated in the terminal cavities in the PDC receptacle. 5. Install the cover onto the PDC. 6. Reconnect the battery negative cable. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions Interior Lighting Module: Diagram Information and Instructions Introduction General Information (Part 1 Of 2) Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 175 General Information (Part 2 Of 2) Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Function Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 176 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 177 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 178 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 179 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 180 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 181 Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 182 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 183 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 184 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 185 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 186 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Terminal/Connector Repair-Thomas and Betts Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 187 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector. Removing Wire Terminal 4. Insert the probe end of Special Tool 6934 into the back of the connector cavity. 5. Grasp the wire and Special Tool 6934 and slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal. 7. Install the wire and terminal in the connector. Fully seat the terminal in the connector. Single Lock Tab 8. Push in the single lock tab on the side of the connector. Wiring Repair Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 188 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 189 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 190 Interior Lighting Module: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 191 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 192 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Locations 8w-10-2 Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Locations > Page 196 Trailer Lighting Relay: Diagrams Power Distribution Center (PDC) Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Locations > Page 197 Trailer Tow Relay Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block Junction Block Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 203 Spare Relay Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Technical Service Bulletins > Wiper Module - CTM Mandatory PROM Update Technical Service Bulletin # 08-43-99 Date: 991217 Wiper Module - CTM Mandatory PROM Update NUMBER: 08-43-99 GROUP: Electrical DATE: Dec. 17, 1999 SUBJECT: Central Timer Module Software Update When A Wiper Module Is Replaced OVERVIEW: This bulletin involves selectively erasing and reprogramming the Central Timer Module (CTM) with new software (EEPROM changes). MODELS: 1998 - 1999 (BR/BE) Ram Trucks NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH REMOTE KEYLESS ENTRY. DISCUSSION: Due to a design change in MOPAR replacement wiper modules, the CTM must be updated with new software in order to allow the wiper module to function properly. This following Repair Procedure must be performed any time the wiper module is replaced. EQUIPMENT REQUIRED: 1 CH6OOO Scan Tool (DRB III) 1 CH7035 General Purpose Interface Bus Cable (GPIB) 1 CH7OOO/7001 J1962 Cable 1 CH7025 DIN Power Cable 1 MDS2 NOTE: THE MDS2 AND DRB III ARE REQUIRED TO PERFORM PART OF THIS REPAIR. THE MDS2 SYSTEM MUST BE OPERATING AT CIS CD2046 OR HIGHER. THE DRB III MUST BE OPERATING AT VERSION LEVEL 30.9 OR HIGHER. POLICY: Reimbursabie within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-22-90 0.2 Hrs. FAILURE CODE: FM - Flash Module CTM Flash With Vehicle Connected to DRBIII and MDS2 1. Log onto the MDS2 system. 2. Connect the MDS2 (Mopar Diagnostic System) to the DRB III (Scan Tool) with the GPIB cable. Connect the DRB III to the vehicle with the J1962 cable and switch the ignition key to "ON". 3. Use the arrow keys and select option # 2, "CONNECT TO MDS1 OR MDS2," on the DRB III MAIN MENU SCREEN. 4. Use the arrow keys and select option # 2, "RUN MDS2 APPLICATION," on the DRB III. NOTE: ONCE MDS2, DRB III, AND VEHICLE COMMUNICATION HAS BEEN ESTABLISHED, THE "CANNOT READ VIN FROM DRB III" MESSAGE (ON THE MDS2) WILL BE REPLACED BY THE VEHICLE VIN. PRESS THE "OK" BUTTON ON THE MDS2 TO REQUEST A MDS2 SESSION FOR THE VEHICLE VIN INDICATED. PRESS THE "OK" BUTTON WHEN ASKED TO BEGIN SESSION. 5. Push the FLASH tab on the MDS2. NOTE: A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVELS AS LISTED EARLIER IN THIS BULLETIN. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Technical Service Bulletins > Wiper Module - CTM Mandatory PROM Update > Page 210 6. Select "READ PART NUMBERS FROM VEHICLE" and click "SHOW UPDATES" on the MDS2. NOTE: A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVELS AS LISTED EARLIER IN THIS BULLETIN. 7. Select the new CTM software part number with the light pen and click UPDATE CONTROLLER SOFTWARE. 8. The MDS2 and DRB III will download software files to the DRB Ill® and program CTM in approximately 30 seconds. 9. When MDS2 status box reads "Check DRB Screen For Important Instructions," proceed with the instructions identified on the DRB III screen. CTM Flash With DRBIII In Disconnected Mode 1. Log onto the MDS2 system. 2. A MDS2 session can be started by either entering the VIN or by selecting the appropriate Year, Model, and Engine. CAUTION: MDS2 SYSTEM SOFTWARE OPERATING AT CIS CD2046 WILL NOT DISPLAY ANY AVAILABLE CTM FLASHES WHEN A SESSION IS STARTED BY SELECTING YEAR, MODEL, AND ENGINE FOR 1998 5.9L CUMMINS 16 (12 VALVE ENGINE). SELECT THE 1998 5.9L 24 VALVE CUMMINS ENGINE IF IT BECOMES NECESSARY TO FLASH A CTM ON A 1998 5.9L CUMMINS 16 (12 VALVE ENGINE). ALL SUBSEQUENT (CIS CD2047 OR HIGHER) MDS2 RELEASES WILL FUNCTION PROPERLY. 3. Connect the DRB III to the MDS2 (Mopar Diagnostic System) with the GPIB cable and the DIN cable. 4. Use the arrow keys and select option # 2, "CONNECT TO MDS1 OR MDS2," on the DRB III MAIN MENU SCREEN 5. Use the arrow keys and select option # 2, "RUN MDS2 APPLICATION," on the DRB III. 6. Once the vehicle information has been entered, push the FLASH tab on the MDS2. NOTE: A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVELS AS LISTED EARLIER IN THIS BULLETIN. 7. Using the light pen, scroll to the bottom of the list of available flashes and select all available CTM software part numbers, then click DOWNLOAD SOFTWARE TO DRB III. It will take less than one minute to download the software into the DRB III. NOTE: PART NUMBERS LISTED ARE SOFTWARE PART NUMBERS ONLY AND MAY NOT MATCH THE ACTUAL CTM PART NUMBER IDENTIFIED ON THE CTM. IN ADDITION, THE SOFTWARE PART NUMBER WILL NOT MATCH THE SOFTWARE VERSION NUMBER THAT WILL BE IDENTIFIED WHEN USING DRB III "STAND ALONE" MODE TO COMMUNICATE TO THE CTM. 8. Once the software has been downloaded, a dialog box will appear identifying that the download was successful. Select OK. 9. Disconnect the DRB III from the MDS2 and connect the DRB III to the vehicle. 10. Connect the DRB III to the vehicle and switch the ignition key to the RUN position. 11. Use the arrow keys and select option # 2, "CONNECT TO MDS1 OR MDS2," on the DRB III MAIN MENU SCREEN. 12. Use the arrow keys and select option # 2, "RUN MDS2 APPLICATION," on the DRB III. 13. Wait for the "MDS2 diagnostic mode" menu to appear on the DRB III. 14. Use the arrow keys and select option # 2, "PROGRAM VEHICLE CONTROLLERS," from the DRB III menu screen. 15. If the vehicle is equipped with a CTM, the CTM software part number will be displayed on the DRB III. Select the CTM flash software part number. 16. Use the Page FWD key on the DRB III to download the software into the CTM. A status screen will display "UPDATE IN PROGRESS" as the software is downloaded into the CTM. 17. To have the DRB III properly verify the CTM software part number, turn the ignition key to OFF when prompted by DRB III. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Technical Service Bulletins > Wiper Module - CTM Mandatory PROM Update > Page 211 18. Turn the ignition key to back to RUN when the prompted by DRB III. The DRB III will then confirm that the download was successful by displaying the message CTM REPROGRAMMING WAS SUCCESSFUL. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Service Precautions > Vehicle Damage Warnings Central Timer Module: Service Precautions Vehicle Damage Warnings Before disconnecting any control module, make sure the ignition is OFF. Failure to do so could damage the module. When testing voltage or continuity at any control module, use the terminal side (not the wire end) of the connector. Do not probe a wire through the insulation; this will damage it and eventually cause it to fail because of corrosion. Be careful when performing electrical tests so as to prevent accidental shorting of terminals. Such mistakes can damage fuses or components. Also, a second code could be set, making diagnosis of the original problem more difficult. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Service Precautions > Vehicle Damage Warnings > Page 214 Central Timer Module: Service Precautions Road Testing A Complaint Vehicle Some complaints will require a test drive as part of the repair verification procedure. The purpose of the test drive is to try to duplicate the diagnostic code or symptom condition. CAUTION: BEFORE ROAD TESTING A VEHICLE, BE SURE THAT ALL COMPONENTS ARE REASSEMBLED.DURING THE TEST DRIVE, DO NOT TRY TO READ THE DRB SCREEN WHILE IN MOTION. DO NOT HANG THE DRB FROM THE REAR VIEW MIRROR OR OPERATE IT YOURSELF. HAVE AN ASSISTANT AVAILABLE TO OPERATE THE DRB. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Service Precautions > Page 215 Central Timer Module: Application and ID ACM Airbag Control Module AECM Airbag Electronic Control Module ASDM Airbag System Diagnostic Module CCD Chrysler Collision Detection (vehicle communications bus) CTM Central Timer Module DAB Driver Airbag DLC Data Link Connector IEM Integrated Electronic Module also called Low Line or Base Central Timer Module JB Junction Block MIC Mechanical Instrument Cluster PAB Passenger Airbag PCM Powertrain Control Module PDC Power Distribution Center RKE Remote Keyless Entry SCTM Seat Belt Control Timer Module SQUIB also called Initiator (located in rear of airbag module) VTSS Vehicle Theft Security System Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Description and Operation > Airbag System Central Timer Module: Description and Operation Airbag System Airbag System Description The Airbag Control Module (ACM) is secured to a bracket on the floor panel transmission tunnel below the instrument panel inside the vehicle. The ACM mounting bracket also serves as the instrument; panel center support. The ACM contains a microprocessor, the impact sensor, and energy storage capacitor. The microprocessor contains the air-bag system logic. The ACM system logic includes On-Board Diagnostics (OBD) capability, and communicates with the instrument cluster circuitry on the Chrysler Collision Detection (CCD) data bus to control the airbag indicator lamp. The microprocessor in the ACM monitors the impact sensor signal and the airbag system electrical circuits to determine the system readiness. If the ACM detects a monitored system fault, it sends messages to the instrument cluster on the CCD data bus to turn ON the airbag indicator lamp. A pre-programmed decision algorithm in the ACM microprocessor determines when the deceleration rate signaled by the impact sensor indicates an impact that is severe enough to require airbag system protection. when the programmed conditions are met, the ACM sends and electrical signal to deploy the airbag system components. Only one impact sensor is used in this airbag system. The impact sensor is an accelerometer that senses the rate of the vehicle deceleration, which provides verification of the direction and severity of an impact. The impact sensor is calibrated for the specific vehicle, and is only serviced as a unit with the ACM. The ACM also contains an energy-storage capacitor. This capacitor stores enough electrical energy to deploy the airbags, for one second following a battery disconnect or failure during and impact. The purpose of the capacitor is to provide airbag system protection in a severe secondary impact if the initial impact has damaged or disconnected the battery, but was not severe enough to deploy the airbags. THE AIRBAG SYSTEM IS A SENSITIVE,COMPLEX ELECTROMECHANICAL UNIT.BEFORE ATTEMPTING TO DIAGNOSE OR SERVICE ANY AIRBAG SYSTEM OR RELATED STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENTS YOU MUST FIRST DISCONNECT AND ISOLATE THE BATTERY NEGATIVE ROUND CABLE. THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO CHARGE BEFORE FURTHER SYSTEM SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO DO THIS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. NEVER STRIKE OR KICK THE AIRBAG CONTROL MODULE, AS IT CAN DAMAGE THE IMPACT SENSOR OR AFFECT ITS CALIBRATION. IF AN AIRBAG CONTROL MODULE IS ACCIDENTALLY DROPPED DURING SERVICE, THE MODULE MUST BE SCRAPPED AND REPLACED WITH A NEW UNIT. The AIRBAG warning lamp is the only point at which the customer can observe "symptoms" of a system malfunction. Whenever the ignition key is turned to the "RUN" or "START" position, the MIC performs a lamp check by turning the AIRBAG warning lamp ON for 6-8 seconds. If the lamp remains OFF; it means that the ACM has checked the system and found it to be free of discernible malfunctions. If the lamp remains ON, there could be an active fault in the system or the MIC lamp circuit may be internally shorted to ground, If the lamp comes on and stays ON for a period longer than 6-8 seconds then goes OFF; there is usually an intermittent problem in the system. The MIC monitors the airbag warning lamp and seat belt warning lamp during the bulb check for a defective bulb or lamp driver circuit. The MIC tests the airbag lamp during the cluster bulb check and substitutes the seat belt lamp if the airbag lamp is defective. If the airbag lamp is defective the MIC will turn the seat belt light ON and OFF approximately 30 times to warn the driver that the airbag lamp is defective. The lamp status is sent to the ACM continuously via a CCD bus message. The seat belt lamp acts as a backup in the event that the AIRBAG lamp is defective. This information is sent to the ACM continuously via a CCD bus message. Perform the WARNING LAMP BULB OR DRIVER procedure in this book to find the cause of any customer complaint regarding the AIRBAG warning lamp, such as: - warning lamp does not illuminate - warning lamp stays illuminated with no active DTC's Club cab and quad cab models of this vehicle are equipped with a structural seat belt system. The structural seat belt system includes a Seatbelt Control Timer Module (SCTM). The SCTM has a hardwired input to the ACM. If a fault input form the SCTM is detected, or the SCTM is not connected, the ACM sends a message to the instrument cluster on the CCD data bus to turn ON the seat belt reminder lamp. See Seat Belt Control Timer Module. ACM cannot be repaired or adjusted and, if damaged or faulty, it must be replaced. Driver Airbag Module (DAB) The airbag protective trim cover is the most visible part of the driver side airbag system. The module is mounted directly to the steering wheel. Located under the trim cover are the horn switch, the airbag cushion, and the airbag cushion supporting components. The airbag module includes a housing to which the cushion and inflator are attached and sealed. The airbag module cannot be repaired, and must be replaced if deployed or in any way damaged. The inflator assembly is mounted to the back of the airbag module. The inflator seals the hole in the airbag cushion so it can discharge the gas it produces directly into the cushion when supplied with the proper electrical signal. The protective trim cover is fitted to the front of the airbag module and forms a decorative cover in the center of the steering wheel. Upon airbag deployment, this cover will split at a predetermined breakout line. THE AIRBAG MODULE INFLATOR ASSEMBLY CONTAINS SODIUM AND POTASSIUM NITRATE. THESE MATERIALS ARE Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Description and Operation > Airbag System > Page 218 POISONOUS AND EXTREMELY FLAMMABLE. CONTACT WITH ACID, WATER, OR HEAVY METALS MAY PRODUCE HARMFUL AND IRRITATING GASES (SODIUM HYDROXIDE IS FORMED IN THE PRESENCE OF MOISTURE) OR COMBUSTIBLE COMPOUNDS. IN ADDITION, THE PASSENGER AIRBAG MODULE CONTAINS ARGON GAS PRESSURIZED OVER 2500 PSI. DO NOT ATTEMPT TO DISMANTLE AN AIRBAG MODULE OR TAMPER WITH ITS INFLATOR. DO NOT PUNCTURE, INCINERATE, OR BRING INTO CONTACT WITH ELECTRICITY. DO NOT STORE AT TEMPERATURE EXCEEDING 93°C (200°F). Clockspring The clockspring is mounted on the steering column behind the steering wheel. This assembly consists of a plastic housing which contains a flat, ribbon-like, electrically conductive tape that winds and unwinds with the steering wheel rotation. The clockspring is used to maintain a continuous electrical circuit between the instrument panel wire harness and the driver side airbag module, the horn switch, and the vehicle speed control switches ON vehicles that are so equipped. The clockspring must be properly centered when it is installed on the steering column following any service removal, or it will be damaged. The clockspring cannot be repaired; it must be replaced. Passenger Airbag Module (PAB) The airbag door in the instrument panel top cover above the glove box is the most visible part of the passenger side airbag system. Located under the airbag door is the airbag cushion and it's supporting components. The airbag module includes a housing to which the cushion and inflator are attached and sealed. The airbag module includes a housing to which the cushion and inflator are attached and sealed. The airbag module cannot be repaired, and must be replaced if deployed or in any way damaged. The inflator assembly is mounted to the back of the airbag module. The inflator includes a small canister of highly compressed argon gas. The inflator seals the hole in the airbag cushion so it can discharge the compressed gas it contains directly into the cushion when supplied with the proper electrical signal. The airbag door has a living hinge at the top, which is secured to the instrument panel top cover. The door also has predetermined breakout lines concealed beneath its decorative cover. Upon airbag deployment, the airbag door will split at the breakout lines and the door will pivot out of the way. The airbag module is secured at the bottom to the steel structural base of the instrument panel above the glove box opening. The airbag door is serviced as a unit with the passenger side airbag module, and includes the two passenger heating and air conditioning panel outlet housings. Following an airbag deployment, the airbag module and the instrument panel assembly must be replaced. Passenger Airbag On/Off Switch A passenger Airbag On/Off Switch located on the instrument panel allows the passenger airbag module to be turned OFF when certain child restraint devices are being used in the right front seating position. The switch is equipped with a key cylinder so that the switch position can only be changed using an ignition key. When the ignition switch is in the On position and the passenger side airbag is OFF, a Light-Emitting Diode (LED) illuminates an "Off" indicator lamp on the faceplate of the switch. The passenger side airbag ON/OFF switch is located on the instrument panel. To turn OFF the passenger side airbag, turn the key actuator switch from the vertical position to a slanted position (pointing to the "Off" light indicator), approximately 45 degrees clockwise, remove the key completely from the switch and verify that the switch actuator hole stays in the new position (45 degrees clockwise from vertical). The switch is spring loaded to the "ON" position. It will return to the "ON" position unless you remove the key. When the IGNITION is ON, this procedure will illuminate the "OFF" light indicator on the passenger airbag ON/OFF switch. To re-enable the passenger side airbag, reverse the procedure above so that the key switch actuator is returned to a vertical position. NOTE: Do not turn ignition ON with key in Switch. Do not turn switch with ignition ON. Do not leave key in switch. Do not leave the key in the key actuator under any condition. THE KEY MUST ALWAYS BE REMOVED FROM THE PASSENGER AIRBAG ON/OFF SWITCH KEY CYLINDER AFTER THE SWITCH HAS BEEN USED. The Passenger Airbag On/Off Switch cannot be adjusted or repaired and, if faulty or damaged, the switch must be replaced THE AIRBAG MODULE INFLATOR ASSEMBLY CONTAINS SODIUM AZIDE AND POTASSIUM NITRATE. THESE MATERIALS ARE POISONOUS AND EXTREMELY FLAMMABLE. CONTACT WITH ACID, WATER, OR HEAVY METALS MAY PRODUCE HARMFUL AND IRRITATING GASES (SODIUM HYDROXIDE IS FORMED IN THE PRESENCE OF MOISTURE) OR COMBUSTIBLE COMPOUNDS. IN ADDITION, THE PASSENGER AIRBAG MODULE CONTAINS ARGON GAS PRESSURIZED TO OVER 2500 PSI. DO NOT ATTEMPT TO DISMANTLE AN AIRBAG MODULE OR TAMPER WITH ITS INFLATOR. DO NOT PUNCTURE, INCINERATE, OR BRING INTO CONTACT WITH ELECTRICITY DO NOT STORE AT TEMPERATURE EXCEEDING 93°C (200°F). REPLACE AIRBAG SYSTEM COMPONENTS ONLY WITH PARTS SPECIFIED IN THE CHRYSLER MOPAR PARTS CATALOG. SUBSTITUTE PARTS MAY APPEAR INTERCHANGEABLE, BUT INTERNAL DIFFERENCES MAY RESULT IN INFERIOR OCCUPANT PROTECTION. THE FASTENERS, SCREWS, AND BOLTS ORIGINALLY USED FOR THE AIRBAG SYSTEM COMPONENTS HAVE SPECIAL COATINGS AND ARE SPECIFICALLY DESIGNED FOR THE AIRBAG BAG SYSTEM. THEY MUST NEVER BE REPLACED Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Description and Operation > Airbag System > Page 219 WITH ANY SUBSTITUTES. ANY TIME A NEW FASTENER IS NEEDED, REPLACE IT WITH THE CORRECT FASTENERS PROVIDED IN HE SERVICE PACKAGE OR SPECIFIED IN THE CHRYSLER MOPAR PARTS CATALOG. Seat Belt Control Timer Module The Seat Belt Control Timer Module (SCTM) is secured to a bracket underneath the front edge of the front seat center cushion. The SCTM mounting bracket also serves as the support for the slide-out seat cup holder unit. The SCTM controls the supply of battery current to both of the front seat belt retractor latch solenoids. The SCTM contains an electromechanical Gravity (G)-sensor and an electronic timer circuit. The SCTM monitors the ignition switch state and both door jamb switches through hard-wired inputs. In response to those inputs, the SCTM controls hard-wired outputs to both seat belt retractor latch solenoids. The SCTM also sends diagnostic outputs to the Airbag Control Module (ACM) over a hard-wired fault circuit. The SCTM provides battery current to energize the seat belt retractor latch solenoids whenever the ignition switch is in the On or Accessory position, unless the G-sensor input indicates a vehicle condition that requires the set belt retractor to be latched. When the seat belt retractor latch solenoids are energized the retractor spools are unlatched, and the seat belt webbing can be extracted from the retractor. When the solenoids are deenergized the retractor spools latch, preventing the seat belt webbing from being extracted further from the retractor. This logic ensures that the seat belts will latch and/or remain latched if battery power is lost during a vehicle collision. The electromechanical G-sensor within the SCTM monitors the rate of vehicle acceleration and de-acceleration in any horizontal direction. The G-sensor also responds to the horizontal attitude of the vehicle, If the G-sensor monitors a gravity force of greater than about 0.7G in any horizontal direction, or the vehicle is tilted in any direction at an angle of greater than about 45 degrees, the SCTM will de-energize (lock) the seat belt retractor latch solenoids. The SCTM electronic timer circuit provides the vehicle occupants with the ability to extract the seat belt webbing from the retractor spool for a time period of about 30 minutes after the ignition switch is turned to the Off position. The electronic timer circuit also monitors the state of the door jamb switches, and unlatches the seat belt retractors after either door jamb switch cycles from open to closed or from closed to open. Each time the SCTM receives and input indicating a change in the state of a monitored switch, the 30 minute unlatch timer starts again. The timer also is used to de-energize the retractor latch solenoids after about 30 minutes, and prevent the battery from being drained while the vehicle is not being driven. The hard wired SCTM output to the ACM is used to indicate whether a fault condition is present in the structural seat belt control system. The ACM monitors the input from the SCTM and sends the proper messages to the instrument cluster on the Chrysler Collision Detection (CCD) data bus to turn the seat belt reminder lamp ON or OFF. If the ACM receives a fault input or does not detect any input from the SCTM, it sets a fault code and sends messages to the instrument cluster to turn the lamp ON. The SCTM cannot be repaired. If faulty or damaged, it must be replaced. Seat Belt Control System Test Mode The structural seat belt control system has a test mode feature. This feature allows the seat belt control system to be tested from proper operation while the vehicle is stationary by overriding the normal Seat Belt Control Timer Module (SCTM) control functions. The seat belt system and the airbag system must be tested for proper operation following the service of any seat belt control system or airbag system component. See Airbag Systems for more information on testing of the airbag system. This test mode will confirm the following: Both door jamb switches and their input circuits to the SCTM are functional. - The fused B(+), fused ignition switch output (RUN/ACC), and ground circuits to the SCTM are functional. - The SCTM fault circuit to the Airbag Control Module (ACM), the ACM, the Chrysler Collision Detection (CCD) data bus, and the seat belt reminder lamp in the instrument cluster are functional. - Both seat belt retractor latch solenoids and their circuits are functional and can be activated by the SCTM. To initiate the structural seat belt control system test mode, proceed as follows: 1. If the structural seat belt controls system test mode has not been performed previously within the past 72 hours, reset the SCTM by removing the Ignition-Off Draw (IOD) fuse from the junction block, the reinstalling it. (Ignition must be OFF). 2. Sit in the driver side front seat of the vehicle and close all doors. 3. Push in the cigar lighter, turn the windshield wipers on "HIGH". 4. Within five seconds the ignition switch must be cycled On, Off, On, Off, On, Off, and then finally back to On position. Leave the ignition switch in the On position for the remainder of this procedure. This action enters the seat belt control system into its test mode for a maximum of five minutes. After five minutes, the seat belt control system will automatically return to its normal operating mode. 5. The seat belt reminder lamp should light shortly after entering the test mode to confirm that the seat belt control system is in the test mode, and that the seat belt control system fault circuit is functional. If the lamp fails to light, use a DRB scan tool and the proper Diagnostic Procedures to diagnose the SCTM fault circuit to the ACM, the ACM, and the CCD data bus. 6. Open the driver side front door. Check that both the passenger and driver side outboard front seat belt retractors are unlatched by slowly pulling the seat belt webbing out of the retractor. If only one retractor is unlatched, the latched retractor and circuit must be diagnosed. See Seat Belt Control System in the appropriate service manual for more information. If both retractors are latched, see Seat Belt Control Timer Module in the Diagnosis and Testing. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Description and Operation > Airbag System > Page 220 7. Close the drive side from door. Check that both the passenger and driver side outboard front seat belt retractors are latched by slowly pulling the seat belt webbing out of the retractor. If only one retractor is latched, the unlatched retractor and circuit must be diagnosed. See Seat Belt Retractor latch Solenoid in the Diagnosis and Testing. If both retractors are unlatched, see Seat Belt Control Timer Module in the Diagnosis and Testing. 8. Repeat steps # 6 and # 7, but open and close the passenger side front door instead of the driver side. 9. Turn the ignition switch to the Off position. This will cause the seat belt control system to exit its test mode and return to normal operation. 10. Turn the ignition switch back to the On position. The seat belt reminder and airbag indicator lamps should turn OFF shortly after their normal display functions (about six and seven seconds, respectively). If either lamp remains lighted, use a DRB scan tool and the proper Diagnostic Procedures to diagnose the SCTM fault circuit to the ACM, the airbag system, the ACM, and the CCD data bus. 11. If the seat belt control system test mode has timed out prior to completion of the tests (about five minutes after the test was initiated), go back to step # 2. The SCTM is programmed to consider certain parameters as an indication of a faulty Gravity (G)-sensor. In some peculiar vehicle use situations these parameters may be exceeded, causing the seat belt reminder lamp to illuminate indicating an SCTM fault, and them extinguish for no apparent reason. The following parameters should be considered if an intermittent seat belt reminder lamp illumination complaint is being diagnosed, and the test mode reveals no problems with the structural seat belt control system operation. - If the SCTM monitors ten ignition cycles without input from the G-sensor indicating that the vehicle has accelerated or decelerated sufficiently to require the seat belts to be latched. An ignition cycle is defined as: The ignition switch turned to the On position for at least thirty minutes, followed by the ignition switch being turned to the Off position. The SCTM considers this a G-sensor fault because it would normally be expected that the seat belts would require latching at some point while driving, within ten ignition cycles. The SCTM will discontinue the fault signal and reset the ignition cycle counter to zero as soon as it sees a "normal" G-sensor input. - If the SCTM monitors that the G-sensor input has required the seat belts to remain latched for more than about four seconds. The SCTM will discontinue the fault signal as soon as it sees a "normal" G-sensor input. Airbag Diagnostic Trouble Codes The Airbag Control Module may report any of the following diagnostic trouble codes. Airbag diagnostic trouble codes consist of active and stored codes. If more than one code exists, diagnostic priority should be give to the active codes. Active diagnostic trouble codes for the airbag system are not permanent and will change the moment the reasoning for the code is corrected. In certain test procedures, diagnostic trouble codes are used as a diagnostic tool. For these codes, replace the Airbag Control Module (ACM) even if set intermittently. - ACM ACCELEROMETER......FIRING CAPACITOR LOW - AECM OUTPUT DRIVER CIRCUIT OPEN......LOGIC CAPACITOR LOW - AECM INTERNAL DIAGNOSTIC CODE # 1......SAFING SENSOR SHORTED - WARNING LAMP DRIVER ERROR For these codes, refer to the appropriate diagnostic procedure: - Cluster Message Mismatch - Driver Squib Circuit Open - Driver Squib Circuit Shorted - Driver Squib Circuit Shorted to Battery - Driver Squib Circuit Shorted to Ground - Loss of Ignition Run Only - Loss of Ignition Run/Start - No Cluster CCD Message - Missing or Invalid VIN - Passenger Squib Circuit Open - Passenger Squib Circuit Shorted - Passenger Squib Circuit Shorted to Battery - Passenger Squib Circuit Shorted to Ground - SCTM Failure - SCTM Message Mismatch - VIN Mismatch - Warning Lamp Bulb or Driver Active Codes The code becomes active as soon as the malfunction is detected or key-OFF, whichever occurs first. An active trouble code indicates an on-going malfunction. This means that the defect is currently there every time the airbag control module checks that circuit/function. It is impossible to erase an Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Description and Operation > Airbag System > Page 221 active code; active codes automatically erase by themselves when the reason for the code has been corrected. With the exception of the warning lamp trouble codes or malfunctions, when a malfunction is detected, the airbag lamp remains lit for a maximum of 12 seconds or as long as the malfunction is present. The seat belt lamp replaces the airbag lamp if the airbag lamp is defective. The seat belt lamp pulses ON and OFF 30 times if the airbag warning lamp is defective. Stored Codes Airbag codes are automatically stored in the ACM's memory as soon as the malfunction is detected. The exception is the "Loss of Ignition Run Only" code which is an active code only. A "stored" code indicates there was an active code present at some time. However, the code currently may not be present as an active code, although another active code could be. When a trouble code occurs, the airbag warning lamp illuminates for 2 seconds minimum (even if the problem existed for less than 2 seconds). The code is stored, along with the time in minutes it was active, and the number of times the ignition has been cycled since the problem was last detected. The minimum time shown for any code will be one minute, even if the code was actually present for less than one minute. Thus, the time shown for a code that was present for two minutes 2 seconds, for example, would be three minutes. If a malfunction is detected a diagnostic trouble code is stored and will remain stored as long as the malfunction exists. When and if the malfunction ceases to exist, an ignition cycle count will be initiated for that code. If the ignition cycle count reaches 100 without a reoccurrence of the same malfunction, the diagnostic trouble code is erased and that ignition cycle counter is reset to zero. If the malfunction reoccurs before the count reaches 100, then the ignition cycle counter will be reset and the diagnostic trouble code will continue to be a stored code. If a malfunction is not active while performing a diagnostic test procedure, the active code diagnostic test will not locate the source of the problem. In this case, the stored code can indicate an area to inspect. If no obvious problems are found, erase stored codes, and with the ignition "ON" wiggle the wire harness and connectors, rotate the steering wheel from stop to stop. Recheck for codes periodically as you work through the system. This procedure may uncover a malfunction that is difficult to locate. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Description and Operation > Airbag System > Page 222 Central Timer Module: Description and Operation Interior Lighting The courtesy lights are controlled by the CTM. The door switches are inputs to the CTM and the courtesy lights are outputs. The glove box lamp and the ash receiver lamp (if equipped) are not controlled by the CTM, They are hardwired to individual switches and fuses. The ignition key halo lamp is controlled by the CTM and will remain ON for thirty seconds after the door is closed. The highline CTM also provides for illuminated entry option. If the CTM detects an unlock signal from the RKE transmitter, a door disarm switch input or the door jamb switch input, the interior courtesy lights will be turned ON. The illuminated entry function is canceled if the CTM senses and ignition "ON" condition or the "lock" command from a valid key fob. If a door is left open or the dome lamp switch is left in the "ON" position for more than fifteen minutes, the CTM will extinguish the lamps to avoid discharging the battery. If the lamps are turned ON by rotation of the headlamp panel dimmer switch, the CTM will not be able to turn them OFF. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Description and Operation > Airbag System > Page 223 Central Timer Module: Description and Operation Central Timer Module Central Timer Module Description CENTRAL TIMER MODULE DESCRIPTION Two versions of the Central Timer Module (CTM) are available on this vehicle, a base version and a high-line version. The base version of the CTM is used on base models of the vehicle. It is also sometimes referred to as the Integrated Electronic Module (IEM). The base version of the CTM combines the functions of a chime/buzzer module, an intermittent wipe module, and an ignition lamp time delay relay in a single unit. The base version CTM does not communicate on the CCD bus. The high-line version of the CTM is used on high-line vehicles. The high-line CTM provides all of the functions of the base version CTM, but also is used to control and integrate many of the additional electronic functions and features included on the high-line models. The high-line version of the CTM contains a central processing unit and interfaces with other modules in the vehicle on the Chrysler Collision Detection (CCD) data bus network. The CCD data bus network allows the sharing of sensor information. This helps to reduce wire harness complexity reduce internal controller hardware and reduce component sensor current loads. At the same time, this system provides increased reliability, enhanced diagnostics, and allows the addition of many new feature capabilities. One of the features that the high-line CTM supports and controls is the Vehicle Theft Security System (VTSS). In the VTSS, the CTM receives hard-wired inputs from the door jamb, door lock cylinder, and ignition switches. The programming in the CTM allows it to process the information from these inputs and send control outputs to energize or de-energize the headlamp (or security) relay, horn relay, and the security lamp. The CTM also sends CCD data bus messages to the Powertrain Control Module (PCM) to control the engine no-run feature of the VTSS. The CTM is located on the right side of the steering column behind the kneeblocker on a metal bracket welded to the instrument panel. It contains a white 8-way and a green 14-way connector. For diagnosis of the high-line version of the CTM or the CCD data bus, the use of a DRB scan tool and the proper Diagnostic Procedures are recommended. The CTM cannot be repaired and, if faulty or damaged, it must be replaced. The high-line Central Timer Module (CTM) can also control some features of the audio system when the vehicle is equipped with the optional RAZ radio receiver and remote radio switches. A high-line CTM is used on high-line versions of this vehicle. The CTM combines the functions of a chime/buzzer module, an intermittent wipe module, an illuminated entry module, a remote keyless entry module, and a vehicle theft security system module in a single unit. The high-line CTM also controls and integrates many of the additional electronic functions and features included on models with this option. The RAZ radio receiver with a remote radio switch option is one of the features that the CTM controls. The CTM is programmed to send switch status messages over the Chrysler Collision Detection (CCD) data bus to control the volume, seek, and pre-set station advance functions of the RAZ radio receiver. The CTM monitors the status of the remote radio switches located on the steering wheel through a hard wired circuit. The CTM then sends the proper switch status messages to the radio receiver. The electronic circuitry within the radio receiver responds to the switch status messages it receives by adjusting the radio settings as requested. Refer to Remote Radio Switch Description and Operation for more information on this component. See: Accessories and Optional Equipment/Radio, Stereo, and Compact Disc/Radio/Stereo/Remote Switch In addition radio receivers connected to the CCD data bus have several audio system functions that can be diagnosed using a DRB scan tool. Refer to the proper Diagnostic Procedures for more information on DRB testing of the audio systems. The high-line Central Timer Module (CTM) can also operate the horn system. A high-line CTM is used on high-line versions of this vehicle. The CTM combines the functions of a chime/buzzer module, an intermittent wipe module, an illuminated entry module, a remote keyless entry module, and a vehicle theft security system module in a single unit. The high-line CTM also controls and integrates many of the additional electronic functions and features included on models with this option. The horn relay is one of the hard wired outputs of the CTM. The high-line CTM is programmed to energize or deenergize the horn relay in response to certain inputs from the Vehicle Theft Security System (VTSS) and/or the Remote Keyless Entry (RKE) system. Refer to Vehicle Theft Security System Description and Operation for more information on the VTSS. Refer to Power Lock Systems / Remote Keyless Entry System Description and Operation for more information on the RKE system. See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Keyless Entry/Description and Operation Both the base and the high-line versions of the CTM support the intermittent wipe and wipe-after-wash features, but only the high-line CTM supports the speed sensitive intermittent wipe. The intermit-tent wipe relay is one of the outputs that both the base and the high-line versions of the CTM can control. Each CTM is programmed to energize or de-energize the intermittent wipe relay in response to certain inputs from the windshield wiper and washer switches and from the windshield wiper motor park switch. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Description and Operation > Airbag System > Page 224 For the speed sensitive intermittent wipe feature, the high-line CTM also uses vehicle speed messages, which are received on the CCD data bus from the Powertrain Control Module (PCM). See Wiper System Testing and Inspection for diagnosis of the base version of the CTM. See: Wiper and Washer Systems/Testing and Inspection For diagnosis of the high-line version of the CTM or the CCD data bus, refer to Body Control Module Testing and Inspection. See: Testing and Inspection The CTM cannot be repaired and, if faulty or damaged, it must be replaced. The high-line CTM controls features and functions of the power lock, illuminated entry, and Remote Keyless Entry (RKE) systems. The high-line CTM receives hard-wired inputs from the power lock switches, CCD message inputs from the Powertrain Control Module (PCM) and Airbag Control Module (ACM), and coded radio frequency inputs from the RKE transmitters. In response to those and many other inputs, the internal programming of the CTM sends the proper outputs to control the power lock motors, the headlamp (or security) and horn relays, and the courtesy lamps. Some of the features and functions of the power lock, illuminated entry and RKE systems made possible because of the communication of the CTM on the CCD data bus network include: - A door-lock inhibit feature which prevents the power lock system from being energized with a power door lock switch if the key is in the ignition and/or the headlamps are on. However, the locks can still be operated manually, with a key or energized with the RKE transmitter. - A Panic Mode feature which can provide additional personal security and protection. When the Panic button on the RKE transmitter is depressed the vehicle horn will pulse, the headlights will flash, and the interior lights will illuminate on the vehicle for about three minutes, or until the Panic button is depressed a second time. A vehicle speed of about 24 kilometers-per-hour (15 miles-per-hour) will also cancel the panic mode. - An enhanced accident response feature will unlock both doors, then prevent the power door locks from locking the doors for a predetermined time interval, after receiving a CCD message from the ACM indicating a frontal impact of the vehicle requiring airbag deployment. This feature will also turn on the courtesy lamps ten seconds after receiving the ACM deployment message, if the CCD vehicle speed message from the PCM indicates that the vehicle is not moving. Of course, these responses are dependent upon functional battery power and wiring circuitry following the impact. - Rolling door locks is a programmable feature of the power lock system. This feature will automatically lock all of the doors after the vehicle reaches a speed of about 24 kilometers-per-hour (15 miles-per hour) or greater. This feature will also lock the doors if a door is opened, then closed again, at any speed above 24 kilometers-per-hour (15 miles-per-hour). - A programmable feature of the RKE system is the enabling or disabling of the horn chirp following activation of the RKE Lock function. This feature can be enabled or disabled and, if enabled, the horn chirp duration (twenty or forty milliseconds) can be selected. Both versions of the CTM are mounted under the driver side end of the instrument panel, inboard of the instrument panel steering column opening. Refer to Central Timer Module Replacement of Instrument Panel Systems for the service procedures. The programmable features of the CTM can be enabled or disabled using the DRB scan tool as described in the proper Diagnostic Procedures. For diagnosis of the high-line version of the CTM or of the CCD data bus, a DRB scan tool and the proper Diagnostic Procedures are recommended. The CTM cannot be repaired and, if faulty or damaged, it must be replaced. OPERATION Some of the functions and features that the CTM supports or controls include: Chimes for the following conditions: - Headlamps on with ignition off and driver door open warning - Key in ignition with ignition off and driver door open warning - ABS lamp warning (if the vehicle is so equipped) - Airbag lamp warning - Check engine lamp warning - Check gauges lamp warning - Low fuel lamp warning - Low washer fluid lamp warning - Seat belt reminder lamp warning - Transmission oil temperature lamp warning (automatic transmission) - Courtesy lamp time-out (high-line only) - Ignition key lamp timer - Intermittent wipe control - Enhanced accident response (high-line only) Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Description and Operation > Airbag System > Page 225 - Horn chirp upon door lock with RKE (programmable) (high-line only) - Illuminated entry (high-line only) - Power door lock control (high-line only) - Power lock inhibit (high-line only) - Remote Keyless Entry (RKE) (high-line only) - Remote radio switches (high-line only) - Rolling door locks (programmable) (high-line only) - Speed sensitive intermittent wipe (high-line only) - Vehicle Theft Security System (VTSS) (high-line only) (if the vehicle is so equipped) - Wipe after wash (high-line only). CENTRAL TIMER MODULE DIAGNOSTIC TROUBLE CODES Door Disarm Switch Failure Door lock Switch Failure Door Unlock Switch Failure Wiper Park Switch Failure EEPROM Checksum Failure Internal ROM Test Failure Central Timer Module Diagnostic Trouble Codes Door Disarm Switch Failure Door lock Switch Failure Door Unlock Switch Failure Wiper Park Switch Failure EEPROM Checksum Failure Internal ROM Test Failure Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Description and Operation > Airbag System > Page 226 Central Timer Module: Description and Operation Chime System The chime system is built into the CTM. The system also supports an external chime request from the instrument cluster. This feature allows the instrument cluster to request a chime from the CTM for gauge problems and tell tale warnings. The CTM chime functions will have priority over the MIC chime requests. There are two chime rates, Low; 50 chimes per minute for reminders and High; 80 chimes per minute for serious conditions that require immediate attention. The high rate chime sounds when the key is left in the ignition and the driver doors is open or the headlights are left ON. The low rate chime sounds for any of the other conditions. There is a variable rate feature that allows the chime to sound continuously for key-in and headlamp warning as long as the door is open. The seat belt warning chime is activated for 4 to 6 seconds, and all other chime conditions will activate the chime once at the same time the warning light on the cluster is illuminated. The chime will sound for the following conditions: High Rate Key in Ignition Warning ignition OFF, key in ignition, drivers door open - Ignition OFF, headlamps ON, drivers door open Low Rate - Seat belt warning-6 seconds after key ON (6 to 8 chimes) or until belt is buckled - Airbag lamp illuminated (3 times after prove-out) - Anti-lock lamp illuminated (2 chimes after prove- out if equipped) - Check engine lamp illuminated (2 chimes after prove-out) - Check gauges lamp illuminated (2 chimes) - Engine Temp High--when gauge enters red zone (2 chimes) - Low fuel- when fuel level reaches /8 tank (2 chimes) - Low washer fluid (2 chimes) - Wait to start (diesel only) (2 chimes) - Water in fuel (diesel only) ( 2 chimes) If the ignition switch is turned to the run/start/acc position and the driver's door is closed, then opened, the warning chime is defeated. This allows the doors to be open without the warning chime constantly sounding. The CTM stays in this mode until the ignition switch is turned to the "OFF" position, then normal function will be restored. (Highline CTM only). Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Description and Operation > Airbag System > Page 227 Central Timer Module: Description and Operation Airbag System Description The Airbag Control Module (ACM) is secured to a bracket on the floor panel transmission tunnel below the instrument panel inside the vehicle. The ACM mounting bracket also serves as the instrument; panel center support. The ACM contains a microprocessor, the impact sensor, and energy storage capacitor. The microprocessor contains the air-bag system logic. The ACM system logic includes On-Board Diagnostics (OBD) capability, and communicates with the instrument cluster circuitry on the Chrysler Collision Detection (CCD) data bus to control the airbag indicator lamp. The microprocessor in the ACM monitors the impact sensor signal and the airbag system electrical circuits to determine the system readiness. If the ACM detects a monitored system fault, it sends messages to the instrument cluster on the CCD data bus to turn ON the airbag indicator lamp. A pre-programmed decision algorithm in the ACM microprocessor determines when the deceleration rate signaled by the impact sensor indicates an impact that is severe enough to require airbag system protection. when the programmed conditions are met, the ACM sends and electrical signal to deploy the airbag system components. Only one impact sensor is used in this airbag system. The impact sensor is an accelerometer that senses the rate of the vehicle deceleration, which provides verification of the direction and severity of an impact. The impact sensor is calibrated for the specific vehicle, and is only serviced as a unit with the ACM. The ACM also contains an energy-storage capacitor. This capacitor stores enough electrical energy to deploy the airbags, for one second following a battery disconnect or failure during and impact. The purpose of the capacitor is to provide airbag system protection in a severe secondary impact if the initial impact has damaged or disconnected the battery, but was not severe enough to deploy the airbags. THE AIRBAG SYSTEM IS A SENSITIVE,COMPLEX ELECTROMECHANICAL UNIT.BEFORE ATTEMPTING TO DIAGNOSE OR SERVICE ANY AIRBAG SYSTEM OR RELATED STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENTS YOU MUST FIRST DISCONNECT AND ISOLATE THE BATTERY NEGATIVE ROUND CABLE. THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO CHARGE BEFORE FURTHER SYSTEM SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO DO THIS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. NEVER STRIKE OR KICK THE AIRBAG CONTROL MODULE, AS IT CAN DAMAGE THE IMPACT SENSOR OR AFFECT ITS CALIBRATION. IF AN AIRBAG CONTROL MODULE IS ACCIDENTALLY DROPPED DURING SERVICE, THE MODULE MUST BE SCRAPPED AND REPLACED WITH A NEW UNIT. The AIRBAG warning lamp is the only point at which the customer can observe "symptoms" of a system malfunction. Whenever the ignition key is turned to the "RUN" or "START" position, the MIC performs a lamp check by turning the AIRBAG warning lamp ON for 6-8 seconds. If the lamp remains OFF; it means that the ACM has checked the system and found it to be free of discernible malfunctions. If the lamp remains ON, there could be an active fault in the system or the MIC lamp circuit may be internally shorted to ground, If the lamp comes on and stays ON for a period longer than 6-8 seconds then goes OFF; there is usually an intermittent problem in the system. The MIC monitors the airbag warning lamp and seat belt warning lamp during the bulb check for a defective bulb or lamp driver circuit. The MIC tests the airbag lamp during the cluster bulb check and substitutes the seat belt lamp if the airbag lamp is defective. If the airbag lamp is defective the MIC will turn the seat belt light ON and OFF approximately 30 times to warn the driver that the airbag lamp is defective. The lamp status is sent to the ACM continuously via a CCD bus message. The seat belt lamp acts as a backup in the event that the AIRBAG lamp is defective. This information is sent to the ACM continuously via a CCD bus message. Perform the WARNING LAMP BULB OR DRIVER procedure in this book to find the cause of any customer complaint regarding the AIRBAG warning lamp, such as: - warning lamp does not illuminate - warning lamp stays illuminated with no active DTC's Club cab and quad cab models of this vehicle are equipped with a structural seat belt system. The structural seat belt system includes a Seatbelt Control Timer Module (SCTM). The SCTM has a hardwired input to the ACM. If a fault input form the SCTM is detected, or the SCTM is not connected, the ACM sends a message to the instrument cluster on the CCD data bus to turn ON the seat belt reminder lamp. See Seat Belt Control Timer Module. ACM cannot be repaired or adjusted and, if damaged or faulty, it must be replaced. Driver Airbag Module (DAB) The airbag protective trim cover is the most visible part of the driver side airbag system. The module is mounted directly to the steering wheel. Located under the trim cover are the horn switch, the airbag cushion, and the airbag cushion supporting components. The airbag module includes a housing to which the cushion and inflator are attached and sealed. The airbag module cannot be repaired, and must be replaced if deployed or in any way damaged. The inflator assembly is mounted to the back of the airbag module. The inflator seals the hole in the airbag cushion so it can discharge the gas it produces directly into the cushion when supplied with the proper electrical signal. The protective trim cover is fitted to the front of the airbag module and forms a decorative cover in the center of the steering wheel. Upon airbag deployment, this cover will split at a predetermined breakout line. THE AIRBAG MODULE INFLATOR ASSEMBLY CONTAINS SODIUM AND POTASSIUM NITRATE. THESE MATERIALS ARE POISONOUS AND EXTREMELY FLAMMABLE. CONTACT WITH ACID, WATER, OR HEAVY METALS MAY PRODUCE HARMFUL Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Description and Operation > Airbag System > Page 228 AND IRRITATING GASES (SODIUM HYDROXIDE IS FORMED IN THE PRESENCE OF MOISTURE) OR COMBUSTIBLE COMPOUNDS. IN ADDITION, THE PASSENGER AIRBAG MODULE CONTAINS ARGON GAS PRESSURIZED OVER 2500 PSI. DO NOT ATTEMPT TO DISMANTLE AN AIRBAG MODULE OR TAMPER WITH ITS INFLATOR. DO NOT PUNCTURE, INCINERATE, OR BRING INTO CONTACT WITH ELECTRICITY. DO NOT STORE AT TEMPERATURE EXCEEDING 93°C (200°F). Clockspring The clockspring is mounted on the steering column behind the steering wheel. This assembly consists of a plastic housing which contains a flat, ribbon-like, electrically conductive tape that winds and unwinds with the steering wheel rotation. The clockspring is used to maintain a continuous electrical circuit between the instrument panel wire harness and the driver side airbag module, the horn switch, and the vehicle speed control switches ON vehicles that are so equipped. The clockspring must be properly centered when it is installed on the steering column following any service removal, or it will be damaged. The clockspring cannot be repaired; it must be replaced. Passenger Airbag Module (PAB) The airbag door in the instrument panel top cover above the glove box is the most visible part of the passenger side airbag system. Located under the airbag door is the airbag cushion and it's supporting components. The airbag module includes a housing to which the cushion and inflator are attached and sealed. The airbag module includes a housing to which the cushion and inflator are attached and sealed. The airbag module cannot be repaired, and must be replaced if deployed or in any way damaged. The inflator assembly is mounted to the back of the airbag module. The inflator includes a small canister of highly compressed argon gas. The inflator seals the hole in the airbag cushion so it can discharge the compressed gas it contains directly into the cushion when supplied with the proper electrical signal. The airbag door has a living hinge at the top, which is secured to the instrument panel top cover. The door also has predetermined breakout lines concealed beneath its decorative cover. Upon airbag deployment, the airbag door will split at the breakout lines and the door will pivot out of the way. The airbag module is secured at the bottom to the steel structural base of the instrument panel above the glove box opening. The airbag door is serviced as a unit with the passenger side airbag module, and includes the two passenger heating and air conditioning panel outlet housings. Following an airbag deployment, the airbag module and the instrument panel assembly must be replaced. Passenger Airbag On/Off Switch A passenger Airbag On/Off Switch located on the instrument panel allows the passenger airbag module to be turned OFF when certain child restraint devices are being used in the right front seating position. The switch is equipped with a key cylinder so that the switch position can only be changed using an ignition key. When the ignition switch is in the On position and the passenger side airbag is OFF, a Light-Emitting Diode (LED) illuminates an "Off" indicator lamp on the faceplate of the switch. The passenger side airbag ON/OFF switch is located on the instrument panel. To turn OFF the passenger side airbag, turn the key actuator switch from the vertical position to a slanted position (pointing to the "Off" light indicator), approximately 45 degrees clockwise, remove the key completely from the switch and verify that the switch actuator hole stays in the new position (45 degrees clockwise from vertical). The switch is spring loaded to the "ON" position. It will return to the "ON" position unless you remove the key. When the IGNITION is ON, this procedure will illuminate the "OFF" light indicator on the passenger airbag ON/OFF switch. To re-enable the passenger side airbag, reverse the procedure above so that the key switch actuator is returned to a vertical position. NOTE: Do not turn ignition ON with key in Switch. Do not turn switch with ignition ON. Do not leave key in switch. Do not leave the key in the key actuator under any condition. THE KEY MUST ALWAYS BE REMOVED FROM THE PASSENGER AIRBAG ON/OFF SWITCH KEY CYLINDER AFTER THE SWITCH HAS BEEN USED. The Passenger Airbag On/Off Switch cannot be adjusted or repaired and, if faulty or damaged, the switch must be replaced THE AIRBAG MODULE INFLATOR ASSEMBLY CONTAINS SODIUM AZIDE AND POTASSIUM NITRATE. THESE MATERIALS ARE POISONOUS AND EXTREMELY FLAMMABLE. CONTACT WITH ACID, WATER, OR HEAVY METALS MAY PRODUCE HARMFUL AND IRRITATING GASES (SODIUM HYDROXIDE IS FORMED IN THE PRESENCE OF MOISTURE) OR COMBUSTIBLE COMPOUNDS. IN ADDITION, THE PASSENGER AIRBAG MODULE CONTAINS ARGON GAS PRESSURIZED TO OVER 2500 PSI. DO NOT ATTEMPT TO DISMANTLE AN AIRBAG MODULE OR TAMPER WITH ITS INFLATOR. DO NOT PUNCTURE, INCINERATE, OR BRING INTO CONTACT WITH ELECTRICITY DO NOT STORE AT TEMPERATURE EXCEEDING 93°C (200°F). REPLACE AIRBAG SYSTEM COMPONENTS ONLY WITH PARTS SPECIFIED IN THE CHRYSLER MOPAR PARTS CATALOG. SUBSTITUTE PARTS MAY APPEAR INTERCHANGEABLE, BUT INTERNAL DIFFERENCES MAY RESULT IN INFERIOR OCCUPANT PROTECTION. THE FASTENERS, SCREWS, AND BOLTS ORIGINALLY USED FOR THE AIRBAG SYSTEM COMPONENTS HAVE SPECIAL COATINGS AND ARE SPECIFICALLY DESIGNED FOR THE AIRBAG BAG SYSTEM. THEY MUST NEVER BE REPLACED WITH ANY SUBSTITUTES. ANY TIME A NEW FASTENER IS NEEDED, REPLACE IT WITH THE CORRECT FASTENERS Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Description and Operation > Airbag System > Page 229 PROVIDED IN HE SERVICE PACKAGE OR SPECIFIED IN THE CHRYSLER MOPAR PARTS CATALOG. Seat Belt Control Timer Module The Seat Belt Control Timer Module (SCTM) is secured to a bracket underneath the front edge of the front seat center cushion. The SCTM mounting bracket also serves as the support for the slide-out seat cup holder unit. The SCTM controls the supply of battery current to both of the front seat belt retractor latch solenoids. The SCTM contains an electromechanical Gravity (G)-sensor and an electronic timer circuit. The SCTM monitors the ignition switch state and both door jamb switches through hard-wired inputs. In response to those inputs, the SCTM controls hard-wired outputs to both seat belt retractor latch solenoids. The SCTM also sends diagnostic outputs to the Airbag Control Module (ACM) over a hard-wired fault circuit. The SCTM provides battery current to energize the seat belt retractor latch solenoids whenever the ignition switch is in the On or Accessory position, unless the G-sensor input indicates a vehicle condition that requires the set belt retractor to be latched. When the seat belt retractor latch solenoids are energized the retractor spools are unlatched, and the seat belt webbing can be extracted from the retractor. When the solenoids are deenergized the retractor spools latch, preventing the seat belt webbing from being extracted further from the retractor. This logic ensures that the seat belts will latch and/or remain latched if battery power is lost during a vehicle collision. The electromechanical G-sensor within the SCTM monitors the rate of vehicle acceleration and de-acceleration in any horizontal direction. The G-sensor also responds to the horizontal attitude of the vehicle, If the G-sensor monitors a gravity force of greater than about 0.7G in any horizontal direction, or the vehicle is tilted in any direction at an angle of greater than about 45 degrees, the SCTM will de-energize (lock) the seat belt retractor latch solenoids. The SCTM electronic timer circuit provides the vehicle occupants with the ability to extract the seat belt webbing from the retractor spool for a time period of about 30 minutes after the ignition switch is turned to the Off position. The electronic timer circuit also monitors the state of the door jamb switches, and unlatches the seat belt retractors after either door jamb switch cycles from open to closed or from closed to open. Each time the SCTM receives and input indicating a change in the state of a monitored switch, the 30 minute unlatch timer starts again. The timer also is used to de-energize the retractor latch solenoids after about 30 minutes, and prevent the battery from being drained while the vehicle is not being driven. The hard wired SCTM output to the ACM is used to indicate whether a fault condition is present in the structural seat belt control system. The ACM monitors the input from the SCTM and sends the proper messages to the instrument cluster on the Chrysler Collision Detection (CCD) data bus to turn the seat belt reminder lamp ON or OFF. If the ACM receives a fault input or does not detect any input from the SCTM, it sets a fault code and sends messages to the instrument cluster to turn the lamp ON. The SCTM cannot be repaired. If faulty or damaged, it must be replaced. Seat Belt Control System Test Mode The structural seat belt control system has a test mode feature. This feature allows the seat belt control system to be tested from proper operation while the vehicle is stationary by overriding the normal Seat Belt Control Timer Module (SCTM) control functions. The seat belt system and the airbag system must be tested for proper operation following the service of any seat belt control system or airbag system component. See Airbag Systems for more information on testing of the airbag system. This test mode will confirm the following: Both door jamb switches and their input circuits to the SCTM are functional. - The fused B(+), fused ignition switch output (RUN/ACC), and ground circuits to the SCTM are functional. - The SCTM fault circuit to the Airbag Control Module (ACM), the ACM, the Chrysler Collision Detection (CCD) data bus, and the seat belt reminder lamp in the instrument cluster are functional. - Both seat belt retractor latch solenoids and their circuits are functional and can be activated by the SCTM. To initiate the structural seat belt control system test mode, proceed as follows: 1. If the structural seat belt controls system test mode has not been performed previously within the past 72 hours, reset the SCTM by removing the Ignition-Off Draw (IOD) fuse from the junction block, the reinstalling it. (Ignition must be OFF). 2. Sit in the driver side front seat of the vehicle and close all doors. 3. Push in the cigar lighter, turn the windshield wipers on "HIGH". 4. Within five seconds the ignition switch must be cycled On, Off, On, Off, On, Off, and then finally back to On position. Leave the ignition switch in the On position for the remainder of this procedure. This action enters the seat belt control system into its test mode for a maximum of five minutes. After five minutes, the seat belt control system will automatically return to its normal operating mode. 5. The seat belt reminder lamp should light shortly after entering the test mode to confirm that the seat belt control system is in the test mode, and that the seat belt control system fault circuit is functional. If the lamp fails to light, use a DRB scan tool and the proper Diagnostic Procedures to diagnose the SCTM fault circuit to the ACM, the ACM, and the CCD data bus. 6. Open the driver side front door. Check that both the passenger and driver side outboard front seat belt retractors are unlatched by slowly pulling the seat belt webbing out of the retractor. If only one retractor is unlatched, the latched retractor and circuit must be diagnosed. See Seat Belt Control System in the appropriate service manual for more information. If both retractors are latched, see Seat Belt Control Timer Module in the Diagnosis and Testing. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Description and Operation > Airbag System > Page 230 7. Close the drive side from door. Check that both the passenger and driver side outboard front seat belt retractors are latched by slowly pulling the seat belt webbing out of the retractor. If only one retractor is latched, the unlatched retractor and circuit must be diagnosed. See Seat Belt Retractor latch Solenoid in the Diagnosis and Testing. If both retractors are unlatched, see Seat Belt Control Timer Module in the Diagnosis and Testing. 8. Repeat steps # 6 and # 7, but open and close the passenger side front door instead of the driver side. 9. Turn the ignition switch to the Off position. This will cause the seat belt control system to exit its test mode and return to normal operation. 10. Turn the ignition switch back to the On position. The seat belt reminder and airbag indicator lamps should turn OFF shortly after their normal display functions (about six and seven seconds, respectively). If either lamp remains lighted, use a DRB scan tool and the proper Diagnostic Procedures to diagnose the SCTM fault circuit to the ACM, the airbag system, the ACM, and the CCD data bus. 11. If the seat belt control system test mode has timed out prior to completion of the tests (about five minutes after the test was initiated), go back to step # 2. The SCTM is programmed to consider certain parameters as an indication of a faulty Gravity (G)-sensor. In some peculiar vehicle use situations these parameters may be exceeded, causing the seat belt reminder lamp to illuminate indicating an SCTM fault, and them extinguish for no apparent reason. The following parameters should be considered if an intermittent seat belt reminder lamp illumination complaint is being diagnosed, and the test mode reveals no problems with the structural seat belt control system operation. - If the SCTM monitors ten ignition cycles without input from the G-sensor indicating that the vehicle has accelerated or decelerated sufficiently to require the seat belts to be latched. An ignition cycle is defined as: The ignition switch turned to the On position for at least thirty minutes, followed by the ignition switch being turned to the Off position. The SCTM considers this a G-sensor fault because it would normally be expected that the seat belts would require latching at some point while driving, within ten ignition cycles. The SCTM will discontinue the fault signal and reset the ignition cycle counter to zero as soon as it sees a "normal" G-sensor input. - If the SCTM monitors that the G-sensor input has required the seat belts to remain latched for more than about four seconds. The SCTM will discontinue the fault signal as soon as it sees a "normal" G-sensor input. Airbag Diagnostic Trouble Codes The Airbag Control Module may report any of the following diagnostic trouble codes. Airbag diagnostic trouble codes consist of active and stored codes. If more than one code exists, diagnostic priority should be give to the active codes. Active diagnostic trouble codes for the airbag system are not permanent and will change the moment the reasoning for the code is corrected. In certain test procedures, diagnostic trouble codes are used as a diagnostic tool. For these codes, replace the Airbag Control Module (ACM) even if set intermittently. - ACM ACCELEROMETER......FIRING CAPACITOR LOW - AECM OUTPUT DRIVER CIRCUIT OPEN......LOGIC CAPACITOR LOW - AECM INTERNAL DIAGNOSTIC CODE # 1......SAFING SENSOR SHORTED - WARNING LAMP DRIVER ERROR For these codes, refer to the appropriate diagnostic procedure: - Cluster Message Mismatch - Driver Squib Circuit Open - Driver Squib Circuit Shorted - Driver Squib Circuit Shorted to Battery - Driver Squib Circuit Shorted to Ground - Loss of Ignition Run Only - Loss of Ignition Run/Start - No Cluster CCD Message - Missing or Invalid VIN - Passenger Squib Circuit Open - Passenger Squib Circuit Shorted - Passenger Squib Circuit Shorted to Battery - Passenger Squib Circuit Shorted to Ground - SCTM Failure - SCTM Message Mismatch - VIN Mismatch - Warning Lamp Bulb or Driver Active Codes The code becomes active as soon as the malfunction is detected or key-OFF, whichever occurs first. An active trouble code indicates an on-going malfunction. This means that the defect is currently there every time the airbag control module checks that circuit/function. It is impossible to erase an Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Description and Operation > Airbag System > Page 231 active code; active codes automatically erase by themselves when the reason for the code has been corrected. With the exception of the warning lamp trouble codes or malfunctions, when a malfunction is detected, the airbag lamp remains lit for a maximum of 12 seconds or as long as the malfunction is present. The seat belt lamp replaces the airbag lamp if the airbag lamp is defective. The seat belt lamp pulses ON and OFF 30 times if the airbag warning lamp is defective. Stored Codes Airbag codes are automatically stored in the ACM's memory as soon as the malfunction is detected. The exception is the "Loss of Ignition Run Only" code which is an active code only. A "stored" code indicates there was an active code present at some time. However, the code currently may not be present as an active code, although another active code could be. When a trouble code occurs, the airbag warning lamp illuminates for 2 seconds minimum (even if the problem existed for less than 2 seconds). The code is stored, along with the time in minutes it was active, and the number of times the ignition has been cycled since the problem was last detected. The minimum time shown for any code will be one minute, even if the code was actually present for less than one minute. Thus, the time shown for a code that was present for two minutes 2 seconds, for example, would be three minutes. If a malfunction is detected a diagnostic trouble code is stored and will remain stored as long as the malfunction exists. When and if the malfunction ceases to exist, an ignition cycle count will be initiated for that code. If the ignition cycle count reaches 100 without a reoccurrence of the same malfunction, the diagnostic trouble code is erased and that ignition cycle counter is reset to zero. If the malfunction reoccurs before the count reaches 100, then the ignition cycle counter will be reset and the diagnostic trouble code will continue to be a stored code. If a malfunction is not active while performing a diagnostic test procedure, the active code diagnostic test will not locate the source of the problem. In this case, the stored code can indicate an area to inspect. If no obvious problems are found, erase stored codes, and with the ignition "ON" wiggle the wire harness and connectors, rotate the steering wheel from stop to stop. Recheck for codes periodically as you work through the system. This procedure may uncover a malfunction that is difficult to locate. Interior Lighting The courtesy lights are controlled by the CTM. The door switches are inputs to the CTM and the courtesy lights are outputs. The glove box lamp and the ash receiver lamp (if equipped) are not controlled by the CTM, They are hardwired to individual switches and fuses. The ignition key halo lamp is controlled by the CTM and will remain ON for thirty seconds after the door is closed. The highline CTM also provides for illuminated entry option. If the CTM detects an unlock signal from the RKE transmitter, a door disarm switch input or the door jamb switch input, the interior courtesy lights will be turned ON. The illuminated entry function is canceled if the CTM senses and ignition "ON" condition or the "lock" command from a valid key fob. If a door is left open or the dome lamp switch is left in the "ON" position for more than fifteen minutes, the CTM will extinguish the lamps to avoid discharging the battery. If the lamps are turned ON by rotation of the headlamp panel dimmer switch, the CTM will not be able to turn them OFF. Central Timer Module Description CENTRAL TIMER MODULE DESCRIPTION Two versions of the Central Timer Module (CTM) are available on this vehicle, a base version and a high-line version. The base version of the CTM is used on base models of the vehicle. It is also sometimes referred to as the Integrated Electronic Module (IEM). The base version of the CTM combines the functions of a chime/buzzer module, an intermittent wipe module, and an ignition lamp time delay relay in a single unit. The base version CTM does not communicate on the CCD bus. The high-line version of the CTM is used on high-line vehicles. The high-line CTM provides all of the functions of the base version CTM, but also is used to control and integrate many of the additional electronic functions and features included on the high-line models. The high-line version of the CTM contains a central processing unit and interfaces with other modules in the vehicle on the Chrysler Collision Detection (CCD) data bus network. The CCD data bus network allows the sharing of sensor information. This helps to reduce wire harness complexity reduce internal controller hardware and reduce component sensor current loads. At the same time, this system provides increased reliability, enhanced diagnostics, and allows the addition of many new feature capabilities. One of the features that the high-line CTM supports and controls is the Vehicle Theft Security System (VTSS). In the VTSS, the CTM receives hard-wired inputs from the door jamb, door lock cylinder, and ignition switches. The programming in the CTM allows it to process the Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Description and Operation > Airbag System > Page 232 information from these inputs and send control outputs to energize or de-energize the headlamp (or security) relay, horn relay, and the security lamp. The CTM also sends CCD data bus messages to the Powertrain Control Module (PCM) to control the engine no-run feature of the VTSS. The CTM is located on the right side of the steering column behind the kneeblocker on a metal bracket welded to the instrument panel. It contains a white 8-way and a green 14-way connector. For diagnosis of the high-line version of the CTM or the CCD data bus, the use of a DRB scan tool and the proper Diagnostic Procedures are recommended. The CTM cannot be repaired and, if faulty or damaged, it must be replaced. The high-line Central Timer Module (CTM) can also control some features of the audio system when the vehicle is equipped with the optional RAZ radio receiver and remote radio switches. A high-line CTM is used on high-line versions of this vehicle. The CTM combines the functions of a chime/buzzer module, an intermittent wipe module, an illuminated entry module, a remote keyless entry module, and a vehicle theft security system module in a single unit. The high-line CTM also controls and integrates many of the additional electronic functions and features included on models with this option. The RAZ radio receiver with a remote radio switch option is one of the features that the CTM controls. The CTM is programmed to send switch status messages over the Chrysler Collision Detection (CCD) data bus to control the volume, seek, and pre-set station advance functions of the RAZ radio receiver. The CTM monitors the status of the remote radio switches located on the steering wheel through a hard wired circuit. The CTM then sends the proper switch status messages to the radio receiver. The electronic circuitry within the radio receiver responds to the switch status messages it receives by adjusting the radio settings as requested. Refer to Remote Radio Switch Description and Operation for more information on this component. See: Accessories and Optional Equipment/Radio, Stereo, and Compact Disc/Radio/Stereo/Remote Switch In addition radio receivers connected to the CCD data bus have several audio system functions that can be diagnosed using a DRB scan tool. Refer to the proper Diagnostic Procedures for more information on DRB testing of the audio systems. The high-line Central Timer Module (CTM) can also operate the horn system. A high-line CTM is used on high-line versions of this vehicle. The CTM combines the functions of a chime/buzzer module, an intermittent wipe module, an illuminated entry module, a remote keyless entry module, and a vehicle theft security system module in a single unit. The high-line CTM also controls and integrates many of the additional electronic functions and features included on models with this option. The horn relay is one of the hard wired outputs of the CTM. The high-line CTM is programmed to energize or deenergize the horn relay in response to certain inputs from the Vehicle Theft Security System (VTSS) and/or the Remote Keyless Entry (RKE) system. Refer to Vehicle Theft Security System Description and Operation for more information on the VTSS. Refer to Power Lock Systems / Remote Keyless Entry System Description and Operation for more information on the RKE system. See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Keyless Entry/Description and Operation Both the base and the high-line versions of the CTM support the intermittent wipe and wipe-after-wash features, but only the high-line CTM supports the speed sensitive intermittent wipe. The intermit-tent wipe relay is one of the outputs that both the base and the high-line versions of the CTM can control. Each CTM is programmed to energize or de-energize the intermittent wipe relay in response to certain inputs from the windshield wiper and washer switches and from the windshield wiper motor park switch. For the speed sensitive intermittent wipe feature, the high-line CTM also uses vehicle speed messages, which are received on the CCD data bus from the Powertrain Control Module (PCM). See Wiper System Testing and Inspection for diagnosis of the base version of the CTM. See: Wiper and Washer Systems/Testing and Inspection For diagnosis of the high-line version of the CTM or the CCD data bus, refer to Body Control Module Testing and Inspection. See: Testing and Inspection The CTM cannot be repaired and, if faulty or damaged, it must be replaced. The high-line CTM controls features and functions of the power lock, illuminated entry, and Remote Keyless Entry (RKE) systems. The high-line CTM receives hard-wired inputs from the power lock switches, CCD message inputs from the Powertrain Control Module (PCM) and Airbag Control Module (ACM), and coded radio frequency inputs from the RKE transmitters. In response to those and many other inputs, the internal programming of the CTM sends the proper outputs to control the power lock motors, the headlamp (or security) and horn relays, and the courtesy lamps. Some of the features and functions of the power lock, illuminated entry and RKE systems made possible because of the communication of the CTM on the CCD data bus network include: - A door-lock inhibit feature which prevents the power lock system from being energized with a power door lock switch if the key is in the ignition and/or the headlamps are on. However, the locks can still be operated manually, with a key or energized with the RKE transmitter. - A Panic Mode feature which can provide additional personal security and protection. When the Panic button on the RKE transmitter is Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Description and Operation > Airbag System > Page 233 depressed the vehicle horn will pulse, the headlights will flash, and the interior lights will illuminate on the vehicle for about three minutes, or until the Panic button is depressed a second time. A vehicle speed of about 24 kilometers-per-hour (15 miles-per-hour) will also cancel the panic mode. - An enhanced accident response feature will unlock both doors, then prevent the power door locks from locking the doors for a predetermined time interval, after receiving a CCD message from the ACM indicating a frontal impact of the vehicle requiring airbag deployment. This feature will also turn on the courtesy lamps ten seconds after receiving the ACM deployment message, if the CCD vehicle speed message from the PCM indicates that the vehicle is not moving. Of course, these responses are dependent upon functional battery power and wiring circuitry following the impact. - Rolling door locks is a programmable feature of the power lock system. This feature will automatically lock all of the doors after the vehicle reaches a speed of about 24 kilometers-per-hour (15 miles-per hour) or greater. This feature will also lock the doors if a door is opened, then closed again, at any speed above 24 kilometers-per-hour (15 miles-per-hour). - A programmable feature of the RKE system is the enabling or disabling of the horn chirp following activation of the RKE Lock function. This feature can be enabled or disabled and, if enabled, the horn chirp duration (twenty or forty milliseconds) can be selected. Both versions of the CTM are mounted under the driver side end of the instrument panel, inboard of the instrument panel steering column opening. Refer to Central Timer Module Replacement of Instrument Panel Systems for the service procedures. The programmable features of the CTM can be enabled or disabled using the DRB scan tool as described in the proper Diagnostic Procedures. For diagnosis of the high-line version of the CTM or of the CCD data bus, a DRB scan tool and the proper Diagnostic Procedures are recommended. The CTM cannot be repaired and, if faulty or damaged, it must be replaced. OPERATION Some of the functions and features that the CTM supports or controls include: Chimes for the following conditions: - Headlamps on with ignition off and driver door open warning - Key in ignition with ignition off and driver door open warning - ABS lamp warning (if the vehicle is so equipped) - Airbag lamp warning - Check engine lamp warning - Check gauges lamp warning - Low fuel lamp warning - Low washer fluid lamp warning - Seat belt reminder lamp warning - Transmission oil temperature lamp warning (automatic transmission) - Courtesy lamp time-out (high-line only) - Ignition key lamp timer - Intermittent wipe control - Enhanced accident response (high-line only) - Horn chirp upon door lock with RKE (programmable) (high-line only) - Illuminated entry (high-line only) - Power door lock control (high-line only) - Power lock inhibit (high-line only) - Remote Keyless Entry (RKE) (high-line only) - Remote radio switches (high-line only) - Rolling door locks (programmable) (high-line only) - Speed sensitive intermittent wipe (high-line only) - Vehicle Theft Security System (VTSS) (high-line only) (if the vehicle is so equipped) - Wipe after wash (high-line only). CENTRAL TIMER MODULE DIAGNOSTIC TROUBLE CODES Door Disarm Switch Failure Door lock Switch Failure Door Unlock Switch Failure Wiper Park Switch Failure EEPROM Checksum Failure Internal ROM Test Failure Central Timer Module Diagnostic Trouble Codes Door Disarm Switch Failure Door lock Switch Failure Door Unlock Switch Failure Wiper Park Switch Failure Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Description and Operation > Airbag System > Page 234 EEPROM Checksum Failure Internal ROM Test Failure Chime System The chime system is built into the CTM. The system also supports an external chime request from the instrument cluster. This feature allows the instrument cluster to request a chime from the CTM for gauge problems and tell tale warnings. The CTM chime functions will have priority over the MIC chime requests. There are two chime rates, Low; 50 chimes per minute for reminders and High; 80 chimes per minute for serious conditions that require immediate attention. The high rate chime sounds when the key is left in the ignition and the driver doors is open or the headlights are left ON. The low rate chime sounds for any of the other conditions. There is a variable rate feature that allows the chime to sound continuously for key-in and headlamp warning as long as the door is open. The seat belt warning chime is activated for 4 to 6 seconds, and all other chime conditions will activate the chime once at the same time the warning light on the cluster is illuminated. The chime will sound for the following conditions: High Rate Key in Ignition Warning ignition OFF, key in ignition, drivers door open - Ignition OFF, headlamps ON, drivers door open Low Rate - Seat belt warning-6 seconds after key ON (6 to 8 chimes) or until belt is buckled - Airbag lamp illuminated (3 times after prove-out) - Anti-lock lamp illuminated (2 chimes after prove- out if equipped) - Check engine lamp illuminated (2 chimes after prove-out) - Check gauges lamp illuminated (2 chimes) - Engine Temp High--when gauge enters red zone (2 chimes) - Low fuel- when fuel level reaches /8 tank (2 chimes) - Low washer fluid (2 chimes) - Wait to start (diesel only) (2 chimes) - Water in fuel (diesel only) ( 2 chimes) If the ignition switch is turned to the run/start/acc position and the driver's door is closed, then opened, the warning chime is defeated. This allows the doors to be open without the warning chime constantly sounding. The CTM stays in this mode until the ignition switch is turned to the "OFF" position, then normal function will be restored. (Highline CTM only). Compass Mini-Trip Computer (CMTC) This system, located in the overhead console, displays information on outside temperature, compass direction and trip information. Compass And Temperature Display This display provides the outside temperature in °F or °C and one of eight compass readings to indicate the direction of the vehicle is facing. Trip Odometer (ODO)--Shows the distance traveled in miles or km since the last reset. Average Fuel Economy (AVE ECO) Shows the average fuel economy in MPG (miles per gallon) or L/100 Km since the last reset. Distance to Empty (DTE) Shows the estimated distance that can be traveled with the fuel remaining in the tank. This level calculated using the MPG multiplied by the Fuel Tank Level. Elapsed Time (ET) Shows the accumulated ignition on time whenever the CMTC is powered up until a reset takes place. Step Button Press this button to cycle through all the mini-trip computer displays. US/M Button Press this button to convert all vehicle displays from US to Metric and vice versa. To Reset the Display Press the Step and US/M buttons simultaneously for at least two seconds and all resettable conditions will be reset. This will occur only if a resettable function (AVG ECO, ECO, ET) is currently being displayed. Automatic Compass Calibration This compass is self calibrating which eliminates the need to manually activate the switches on the compass. When the vehicle is new, the compass may appear erratic and the CAL symbol will be displayed. Calibration is automatically detected when the vehicle is drive in a circle at a constant speed between 5 and 11 mph. The diameter of circle should be between 30 and 90 feet, Calibration should take place in an area free of metal and metallic objects and away from power lines. When the calibration process is completed, the CAL light will go OFF and the compass will function normally. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Description and Operation > Airbag System > Page 235 Compass Variance Compass Variance is the difference between Magnetic North and Geographic North. In some areas of the country, the difference between Magnetic and Geographic North is great enough to cause the compass to give false readings. If this occurs, the compass variance must be set. To set the variance: Turn the ignition ON and set display to Comp./Temp. Simultaneously press both the US/M and STEP button for 0 to 2 seconds. The VAR indicator will light up and the current zone number will be displayed. Press STEP button to select the proper variance zone as shown on the map. After 5 seconds of inactivity, the displayed zone will be automatically set, and normal operation will resume. Diagnostics CTM is fully addressable with the DRB III and it is the recommended method for diagnosis. The CTM reports 6 Diagnostic Trouble Codes. All of the inputs to the CTM can be read with the DRB and the outputs can be actuated. If the inputs are OK and the outputs can be cycled with the DRB, the problem is usually the Central Timer Module. DRB III Error Messages and Blank Screen Under normal operation, the DRB will display one of only two error messages: - User-Requested WARM Boot or User-Requested COLD Boot. If the DRB should display any other error message, record the entire display and call the MDS Hotline, or call for information and assistance at 1-800-825-8737. This is a sample of such an error message display: Ver: 2.14 date: 26 Jul93 file: key_itf.cc date: Jul 26 993 line: 548 err: Ox1 User-Requested COLD Boot Press MORE to switch between this display and the application screen. Press F4 when done noting information. DRB III does not power up (Blank Screen) If the LED's do not light or no sound is emitted at start up, check for loose cable connections or a bad cable. Check the vehicle battery voltage (data link connector cavity 6). A minimum of volts is required to adequately power the DRB. If all connections are proper between the DRB and the vehicle or other devices, and the vehicle battery is fully charged, an inoperative DRB may be the result of faulty cable or vehicle wiring. DRB III Display is not visible Low temperatures will affect the visibility of the display. Adjust the contrast to compensate for this condition. Enhanced Accident Response (Highline CTM Only) If the Airbag Control Module (ACM) deploys the airbags, a message is transmitted over the CCD bus to the CTM module to unlock the doors. The interior lights will be turned ON seconds after getting zero speed message on the CCD bus. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Description and Operation > Airbag System > Page 236 In addition to unlocking the doors, the lock feature will be disabled for a predetermined amount of time following the deployment. Once the ignition key has been cycled to the "OFF" position, normal operation will resume. This is a programmable feature. General Information SYSTEM DESCRIPTION AND FUNCTIONAL OPERATION The body system on the 1999 Ram Truck consists of three modules that communicate over the CCD bus (Chrysler Collision Detection multiplex system). There are three additional modules, two types of Powertrain Control Modules (PCM)and the Controller Anti-Lock Brake (CAB) that are not part of the body system, but do utilize the CCD bus for communication. The CAB also utilizes the CCD bus for diagnostics. The PCM sends and receives messages on the CCD bus, however diagnostics are performed through the Serial Communication Interface or SCI, the same as last year. All of the information about the functioning of all the systems is organized, controlled, and communicated by the CCD bus, which is described (CCD Bus) in this general information. Through the CCD bus, information about the operation of vehicle components and circuits is relayed quickly to the appropriate module(s). All modules receive all the information transmitted on the bus even though a module may not require all the information to perform it's function. It will only respond to messages "addressed" to it through a binary coding process. This method of data transmission significantly reduces the complexity of the wiring in the vehicle and the size of wiring harnesses. Gauges The instrument cluster will not store any DTCs. Because the Powertrain Control Module (PCM) gathers all the gauge information and sends it to the cluster via the bus, it is the controller's responsibility to monitor these inputs and store DTCs for them. For this reason the first item to be checked regarding a gauge problem (except oil pressure) should be the engine controller for any DTCs relating to the gauge in question. There are DTCs associated with all the gauges except for the oil pressure gauge. When diagnosing gauges, the input that is used for the gauge message (fuel level sender for example) must be valid. Because of OBD II requirements, most of the information used for monitoring the OBD II system happens to be the same information used by the controller to formulate the gauge bus messages. OBD II Requirements State that the fuel level sender must be checked for rationality. This includes determining if the sending unit voltage is too high or too low or if the voltage hasn't changed over time. If the PCM has determined that the sender information isn't valid, it will send a diagnostic trouble code. The presence or absence of the fuel level sending code in the PCM is and important factor to determine whether a fuel gauge problem is in the sending unit or the cluster. The same situation is used in all cluster diagnostics related to gauge operation with the exception of the oil pressure gauge. OBD II requirements do not include oil pressure monitoring. Therefore, oil pressure diagnostics would dictate that a mechanical oil pressure gauge be attached to the engine for absolute verification of oil pressure readings. Hard Wired Lamps The cluster contains several hard wired lamps described earlier. These lamps are set up in two configurations. Either the cluster supplies power and ground is supplied by the circuit being monitored or the lamp is supplied ground by the cluster and power comes from a module or other device. Refer to the schematic for the specific details on the lamp in question. Verification of the bulb filament may be required in cases of an inoperative lamp. This will require removal of the cluster and the bulb in question. NOTE: ALL RED WARNING LAMPS EXCEPT THE WAIT TO START LAMP ARE LIGHT EMITTING DIODES (LED). LED'S ARE NOT REPLACEABLE, IF DEFECTIVE THE INSTRUMENT CLUSTER MUST BE REPLACED. CCD Controlled Lamps The cluster contains several CCD controlled lamps as described earlier. These lamps are part of the diagnostic self-test. When entering the self-test mode, operation of these lamps can be observed. If the bulb fails to operate during the self-test and the bulb filament is good, the cluster assembly will need to be replaced. NOTE: A FLASHING SEAT BELT LAMP INDICATES THAT THE AIRBAG WARNING LAMP IS NOT OPERATING PROPERLY. Lamps (CCD) The cluster via CCD messages controls the following lamps. They are actuated during the self-test procedure. ABS lamp Brake Warning Low Fuel Warning-Internally Controlled by the Cluster not CCD Airbag Upshift (if equipped) Check Engine Check Gauges Cruise Control Lamp Trans Temp O/D Off (if equipped) Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Description and Operation > Airbag System > Page 237 Water in Fuel Maintenance Required (5.9 Heavy Duty Only) NOTE: THE SEAT BELT AND LOW WASHER SWITCH AND BRAKE WARNING LAMP ARE HARDWIRED TO THE CLUSTER. THE CLUSTER THEN DECIDES IF THE LAMP SHOULD BE ILLUMINATED. Lamps (Hardwired) The following lamps are hardwired in the cluster and are not part of the self-test. Full Time 4WD Seat Belt ABS (amber) High Beam Left Turn Signal Right Turn Signal Security (if equipped) Low Wash Wait to Start Mechanical Instrument Cluster Description The Ram Truck MIC is available in 2 different versions, low line and high line. The lowline cluster has seventeen indicators lamps and the highline has eighteen indicators lamps. The gauges are positioned with information received by the cluster over the CCD bus from the PCM. Some of the warning lamps are hardwired and the cluster using the CCD bus information controls some. The MIC is hardwired to he CTM to provide the warning lamp announcement chimes. There is a self test available for the cluster that will actuate all the gauges at their calibration points. The test will not run if the cluster sees engine RPM or vehicle speed. This test will light all CCD controlled lamps for verification of lamp operation. It also forces the odometer Vacuum Fluorescent Display (VFD) to perform a segment check. The self test routine can be entered by pushing and holding the trip reset button while rotating the ignition key from the "OFF" to the "ON" position. When the word "chec" appears release the knob and the test will continue. The cluster will provide bus bias and termination and the engine controller provides a second termination. If the cluster is disconnected the bus will not be biased. The cluster will be service as an assembly. There will be limited parts available, bulbs and sockets, the front lens, the trip odometer stem cover and the rear cover assembly. No internal parts of the cluster will be serviced. Normal Operation At key ON, the cluster will light the low fuel, seat belt, check gauges, and airbag. As the key is turned farther towards the start position, the check engine, ABS (if equipped) and brake warning lamp will illuminate. The liquid crystal display (VFD) will indicate the mileage stored inside the cluster. If there is a bus failure and the cluster cannot receive distance pulses from the engine controller, the cluster will display the last mileage stored until the ignition is turned OFF. If the cluster is receiving bus messages but is unable to display odometer information because of an internal failure, the odometer display will be blank. Dimming is handled by the potentiometer that controls instrumentation illumination. Also, if there is a CCD bus failure, "no bus" will be displayed on the odometer 20 seconds after the vehicle is started. Power Door Lock System The Central Timer Module (CTM) controls the door lock actuator assemblies to handle locking and unlocking with the key fob or interior switch. There is also a door lock inhibit feature that prevents power locking of the doors if the ignition is OFF and the key is in the ignition. Automatic or rolling locks are included as a DRB programmable feature. If the vehicle is moving approximately 5 mph and approximately degrees of throttle opening is seen by the PCM, (the PCM will send this info to the CTM via the CCD bus) indicating acceleration, the CTM will cycle the lock actuators. Remote Keyless Entry (RKE) /Vehicle Theft Security System (VTSS) The highline CTM provides for Remote Keyless Entry (RKE). The base CTM is not able to provide these functions. The presence of this option dictates that the vehicle is equipped with a high line CTM. The VTSS system monitors the door jamb switches and ignition switch to detect unauthorized entry into the vehicle. Once the vehicle is "armed", any one of these inputs can cause the VTSS system to be tripped. Once tripped, the horn and lights will pulse for 3 minutes and if an attempt is made to start the engine, it will start and stall. If the trigger condition is still present, the lights will continue to flash and return to the "armed" state. The cause of the last 4 alarm triggers is stored by the CTM and may be retrieved by the DRB. The system may be disarmed by either an unlock command from a valid RKE key fob or by using a key in either door. Both front door key cylinders are equipped with disarm switches. There is also a VTSS led on the overhead console that provides information to the driver about the state of the vehicle theft system. The RKE system is placed in the programming mode by the DRB. The system will store up to four key fob codes. Through the DRB, programming of one key fob without deleting the others is possible. If the key fob is stole, all the fob codes stored previously may be erased to provide the owner of the vehicle with an extra sense of security. Trouble Codes Short to Battery - Either or both of the bus wires are shorted to the battery potential. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Description and Operation > Airbag System > Page 238 Short to 5 Volts - Either or both of the bus wires are shorted to a 5 volt potential. Short to Ground - Either or both of the bus wires are shorted to ground. Bus (+) & (-) Shorted Together - The two bus wires are shorted together. No Termination - The bus system has lost connection with all of its terminators. The Instrument Cluster (MIC) and Powertrain Controller (PCM) supply termination for the 1999 Ram Trucks. Bus Bias Level Too Low - Either or both of the bus wire potentials are significantly below their normal 2.5 volts. Bus Bias Level Too High - Either or both of the bus wire potentials are significantly above their normal 2.5 volts. No Bus Bias - The bus system has lost connection with all modules that provide basis. The Instrument Cluster (MIC) provides the CCD bus bias for the 1999 Ram Trucks. Bus (+) Open - The bus (+) wire has lost connection with termination and/or bias. Bus (-) Open - The bus (-) wire has lost connection with termination and/or bias. Not Receiving Bus Messages Correctly - The DRB cannot communicate over the bus and does not know why. Vehicle Communication Chrysler Collision Detection multiplex system (CCD) bus consists of a twisted pair of wires. These wires run from one module to another. They receive and deliver coded information between the modules. The information is coded to identify the message as well as the importance of the message. Where there are multiple messages trying to access the CCD bus at one time, the code determines the message that has the higher priority, and is then allowed to access the bus first. The tow wires of the twisted pair that make up the CCD multiplex system are called "bus +" (bus plus) and "bus -" (bus minus) respectively. Each wire has a measurable voltage level of roughly 2.5 volts. In order to maintain the 2.5 volts on each line and provide a means of transportation for the coded messages, there is a voltage divider network located in the module that supplies bus bias or voltage. Along with the module that supplies bias, some modules provide termination. Bias is the voltage necessary to make the bus operational. At least one point of termination is necessary, some systems use more than one. Some modules are capable of biasing and terminating the bus by themselves. Termination in the circuitry (a 20 ohm resistor placed across the bus) is required to complete the voltage divider network circuit and also provide some electromagnetic protection for the bus. Without termination, voltage on the bus goes approximately 5 volts on one wire and 0 volts on the other wire. In the 1999 Ram Truck, the instrument cluster supplies bus bias and termination and the PCM supplies and additional point of termination. NOTE: COMMUNICATION OVER THE BUS IS ESSENTIAL TO THE PROPER OPERATION OF THE VEHICLES ON-BOARD DIAGNOSTIC SYSTEMS AND THE DRB. PROBLEMS WITH THE OPERATION OF THE BUS OR DRB MUST BE CORRECTED BEFORE PROCEEDING WITH DIAGNOSTIC TESTING. Wiper System The Ram truck equipped with a high line CTM will utilize speed sensitive intermittent wipers. Only a high line CTM will be able to support this feature. A base CTM (IEM) will provide for intermittent wipers without the speed sensitive feature. The low and high speeds are controlled through the wiper stalk switch. The intermittent portion of the wiper control is handled by the CTM through the intermittent wiper relay. When the module detects a decrease in delay time as selected by the driven an immediate wipe of the windshield takes place and the new delay interval is implemented. This feature is present on both the base and highline CTM. When the vehicle is moving at speeds at or below 10 mph, the delay time ranges from 1 to 36 seconds. When the speed rises above 10 mph, the delay times are cut in half for a range of 1/2 to 8 seconds. The speed signal is provided to the CTM from the PCM over the CCD bus. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Testing and Inspection > Reading and Clearing Diagnostic Trouble Codes Central Timer Module: Reading and Clearing Diagnostic Trouble Codes Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Testing and Inspection > Reading and Clearing Diagnostic Trouble Codes > Page 241 Central Timer Module: Symptom Related Diagnostic Procedures AM/FM Switch Inoperative SYMPTOM * AM/FM SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE. POSSIBLE CAUSES - Radio function controls inoperative Balance Dial Inoperative SYMPTOM * BALANCE DIAL INOPERATIVE TEST NOTE This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE. POSSIBLE CAUSES - Radio function controls inoperative CASS Error SYMPTOM CASS ERROR POSSIBLE CAUSES - Defective radio - CASS error CD Eject Switch Inoperative SYMPTOM * CD EJECT SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE. POSSIBLE CAUSES - Radio function controls inoperative CD Error SYMPTOM CD ERROR POSSIBLE CAUSES - Defective radio - CD error Equalizer Inoperative SYMPTOM * EQUALIZER INOPERATIVE TEST NOTE This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE. POSSIBLE CAUSES - Radio function controls inoperative External CD Changer (If Equipped) SYMPTOM * EXTERNAL CD CHANGER (IF EQUIPPED) POSSIBLE CAUSES - CD Cable assembly Defective Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Testing and Inspection > Reading and Clearing Diagnostic Trouble Codes > Page 242 - CD Changer Defective - Defective radio Fader Dial Inoperative SYMPTOM * FADER DIAL INOPERATIVE TEST NOTE This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE. POSSIBLE CAUSES - Radio function controls inoperative FF/RW Switch Inoperative SYMPTOM * FF/RW SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE. POSSIBLE CAUSES - Radio function controls inoperative Hour/Minute Switch Inoperative SYMPTOM * HOUR/MINUTE SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE. POSSIBLE CAUSES - Radio function controls inoperative No Sound From All Speakers SYMPTOM * NO SOUND FROM ALL SPEAKERS POSSIBLE CAUSES - Open radio choke output circuit - Open ground circuit - Open power antenna relay output CKT - radio / radio choke - Open radio 12v output circuit - Power antenna relay output CKT - short to ground - Defective radio - Defective radio choke relay No Sound From One Speaker SYMPTOM * NO SOUND FROM ONE SPEAKER POSSIBLE CAUSES - Speaker (-) circuit open - Rear speaker (+) circuit open - Rear speaker (-) circuit open - Defective front door speaker (+) INOP - Defective front door speaker (-) INOP - Front door speaker (+) circuit open - Front door speaker (-) circuit open - Front door speaker amp (+) faulty - Front door speaker amp (-) faulty - Front door speaker defective - Radio (+) defective - Radio (-) defective Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Testing and Inspection > Reading and Clearing Diagnostic Trouble Codes > Page 243 No Sound From Right/Left Side Speakers SYMPTOM * NO SOUND FROM RIGHT/LEFT SIDE SPEAKERS POSSIBLE CAUSES - Open ground circuit - Open radio choke output CKT - Radio DTC'S present - Defective front door speaker Pause/Play Switch Inoperative SYMPTOM * PAUSE/PLAY SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE. POSSIBLE CAUSES - Radio function controls inoperative Poor Sound Quality All Speakers SYMPTOM * POOR SOUND QUALITY ALL SPEAKERS POSSIBLE CAUSES - Antenna connector connection Defective - Ground circuit open - Radio choke output circuit Defective - Radio choke relay connection Defective - Power antenna relay CKT Defective - Radio connections Defective - Radio relay output Defective - Radio Defective Poor Sound Quality From One Speaker SYMPTOM * POOR SOUND QUALITY FROM ONE SPEAKER POSSIBLE CAUSES - Speaker (+) circuit open - Speaker (-) circuit open - Speaker defective - Radio (-) circuit defective - Door speaker defective - Radio (+) circuit defective PWR Switch Inoperative SYMPTOM * PWR SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE. POSSIBLE CAUSES - Radio function controls inoperative Radio Error SYMPTOM RADIO ERROR POSSIBLE CAUSES - Defective radio - radio error Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Testing and Inspection > Reading and Clearing Diagnostic Trouble Codes > Page 244 Remote Steering Wheel Switches (If Equipped) SYMPTOM * REMOTE STEERING WHEEL SWITCHES (IF EQUIPPED) POSSIBLE CAUSES - MUX control clockspring Defective - Radio control circuit Defective open - Radio control MUX circuit open - Radio control switch ground circuit open - Radio MUX Control circuit Defective - Remote control switch Defective - No response CCD bus failure - Central timer module Defective Scan Switch Inoperative SYMPTOM * SCAN SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE. POSSIBLE CAUSES - Radio function controls inoperative Seek Switch Inoperative SYMPTOM * SEEK SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE. POSSIBLE CAUSES - Radio function controls inoperative Set Switch Inoperative SYMPTOM * SET SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE. POSSIBLE CAUSES - Radio function controls inoperative Shorted Front Channel SYMPTOM SHORTED FRONT CHANNEL POSSIBLE CAUSES - Left front SPKR (+) circuit short to ground - Left front SPKR (-) circuit short to ground - Right front door speaker Defective - Right front SPKR (-) circuit short to ground - Left front door speaker Defective - Right front SPKR (+) circuit short to ground - Right rear speaker (+) CKT- short to ground - Right rear speaker (-) CKT- short to ground - Defective radio Shorted Left Channel SYMPTOM SHORTED LEFT CHANNEL Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Testing and Inspection > Reading and Clearing Diagnostic Trouble Codes > Page 245 POSSIBLE CAUSES - Left front door speaker defective - Left front SPKR (+) circuit short to ground - Left front SPKR (-) circuit short to ground - Left rear speaker (+) CKT- short to ground - Left rear speaker (-) CKT- short to ground - Defective radio Shorted Rear Channel SYMPTOM SHORTED REAR CHANNEL POSSIBLE CAUSES - Left front door speaker defective - Right front door speaker defective - Left rear speaker (+) CKT-short to ground - Left rear speaker (-) CKT-short to ground - Right rear speaker (+) CKT-short to ground - Right rear speaker (-) CKT-short to ground - Defective radio Shorted Right Channel SYMPTOM SHORTED RIGHT CHANNEL POSSIBLE CAUSES - Right front door speaker defective - Right front SPKR (+) circuit short to ground - Right front SPKR (-) circuit short to ground - Right rear speaker (+) CKT-short to ground - Right rear speaker (-) CKT-short to ground - Defective radio Tape Eject Switch Inoperative SYMPTOM * TAPE EJECT SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE. POSSIBLE CAUSES - Radio function controls inoperative Tune Switch Inoperative SYMPTOM * TUNE SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE. POSSIBLE CAUSES - Radio function controls inoperative Volume/Time Switch Inoperative SYMPTOM * VOL/TIME SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE. POSSIBLE CAUSES - Radio function controls inoperative Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Testing and Inspection > Reading and Clearing Diagnostic Trouble Codes > Page 246 1-5 Presets Inoperative SYMPTOM * 1-5 PRESETS INOPERATIVE POSSIBLE CAUSES - Radio function controls inoperative Chime Inoperative - Engine Temperature Critical SYMPTOM * CHIME INOPERATIVE - ENGINE TEMPERATURE CRITICAL POSSIBLE CAUSES - Tone request circuit open - Instrument cluster tone request output defective - CTM fails chime test - PCM DTC coolant temp check Chime Inoperative - Key In Ignition & LF Door Open SYMPTOM * CHIME INOPERATIVE - KEY IN IGNITION & LF DOOR OPEN POSSIBLE CAUSES - Key in ignition switch sense ckt open - Ignition SW - key in switch open - CTM no chime to key in ignition - CTM not responding to key in switch Chime Inoperative at All Times SYMPTOM * CHIME INOPERATIVE AT ALL TIMES POSSIBLE CAUSES - CTM fails internal chime test Chime Inoperative With Exterior Lamps On SYMPTOM * CHIME INOPERATIVE WITH EXTERIOR LAMPS ON POSSIBLE CAUSES - Key in ignition switch sense circuit short to ground - Ignition SW - key in SW shorted - CTM - key in sense short default - Headlamp switch circuit open Chime Inoperative With Low Oil Pressure SYMPTOM * CHIME INOPERATIVE WITH LOW OIL PRESSURE POSSIBLE CAUSES - Oil pressure sender ground circuit open - Tone request circuit open - Instrument cluster - oil press Defective - CTM no response to oil pressure default - CTM fails chime test Chime Sounds With Driver Door Open SYMPTOM * CHIME SOUNDS WITH DRIVER DOOR OPEN POSSIBLE CAUSES - Key in ignition switch sense circuit short to ground - Ignition SW - key in SW shorted Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Testing and Inspection > Reading and Clearing Diagnostic Trouble Codes > Page 247 - CTM - key in sense short default - CTM not responding to key out Open Left Door Ajar Circuit SYMPTOM * OPEN LEFT DOOR AJAR CIRCUIT POSSIBLE CAUSES - Left front ajar switch sense circuit open - Left front door ajar switch sense circuit open - CTM defective - Left front door ajar switch defective, shorted Open Right Door Ajar Circuit SYMPTOM * OPEN RIGHT DOOR AJAR CIRCUIT POSSIBLE CAUSES - RF door ajar switch sense ground circuit open - Right front ajar switch sense circuit open - CTM defective - Right front door ajar switch defective, shorted Shorted Left Door Ajar Circuit SYMPTOM * SHORTED LEFT DOOR AJAR CIRCUIT POSSIBLE CAUSES - Central Timer Module defective - Left front door ajar switch defective, shorted - LF door ajar switch sense circuit short to GND Shorted Right Door Ajar Circuit SYMPTOM * SHORTED RIGHT DOOR AJAR CIRCUIT POSSIBLE CAUSES - RF door ajar switch sense circuit short to GND - CTM defective - Right front door ajar switch defective, shorted All Gauges Inoperative SYMPTOM * ALL GAUGES INOPERATIVE POSSIBLE CAUSES - Fused B (+) circuit from IOD fuse open - No response/CCD bus - Defective instrument cluster Any CCD Cluster Warning Lamp Inoperative SYMPTOM * ANY CCD CLUSTER WARNING LAMP INOPERATIVE POSSIBLE CAUSES - No response/CCD bus - CCD inoperative lamp/bulb defective - CCD lamp cluster input defective - CCD LP cluster test complete - Defective cluster - Instrument cluster defective Any Hard Wired Cluster Warning Lamp Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Testing and Inspection > Reading and Clearing Diagnostic Trouble Codes > Page 248 SYMPTOM * ANY HARD WIRED CLUSTER WARNING LAMP POSSIBLE CAUSES - Defective instrument cluster - Hard wired lamp circuit open - Inoperative lamp/bulb defective One Gauge Not Operating Properly SYMPTOM * ONE GAUGE NOT OPERATING PROPERLY POSSIBLE CAUSES - Gauge not reading 4 psi> engine warm at idle - Oil gauge not reading 4 psi or > at idle - Oil level low - Sensor ground circuit open - Instrument cluster circuit board defective - Oil pressure sensor defective - Charging system defective - Charging system DTC'S - Defective instrument cluster - Instrument cluster defective - Oil pressure sense circuit open - Oil pressure sense signal CKT short to ground - Cooling system operation faulty - Defective JTEC module - Fuel gauge inoperative - Instrument cluster defective - JTEC module defective - Oil pressure switch defective - Pinion factor incorrect - Powertrain Control Module defective Average MPH/Fuel Econ Inoperative or Wrong SYMPTOM * AVERAGE MPH/FUEL ECON INOPERATIVE OR WRONG POSSIBLE CAUSES - Defective Compass/Mini-Trip Computer CMTC Display Shows Failed SYMPTOM * CMTC DISPLAY SHOWS FAILED POSSIBLE CAUSES - Defective CMTC - display failed CMTC Fails to Respond to Instrument Panel Dimming SYMPTOM * CMTC FAILS TO RESPOND TO INSTRUMENT PANEL DIMMING TEST NOTE This symptom is diagnosed using the test * AVERAGE MPH/FUEL ECON INOPERATIVE OR WRONG. POSSIBLE CAUSES - Defective Compass/Mini-Trip Computer CMTC Segments Fail to Light Up SYMPTOM * CMTC SEGMENTS FAIL TO LIGHT UP POSSIBLE CAUSES Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Testing and Inspection > Reading and Clearing Diagnostic Trouble Codes > Page 249 - Defective Compass/Mini-Trip Computer - segments fail to light Distance to Empty Inoperative or Wrong SYMPTOM * DISTANCE TO EMPTY INOPERATIVE OR WRONG TEST NOTE This symptom is diagnosed using the test * AVERAGE MPH/FUEL ECON INOPERATIVE OR WRONG. POSSIBLE CAUSES - Defective Compass/Mini-Trip Computer Elapsed Time Inoperative/Wrong SYMPTOM *ELAPSED TIME INOPERATIVE/WRONG TEST NOTE This symptom is diagnosed using the test* AVERAGE MPH/FUEL ECON INOPERATIVE OR WRONG. POSSIBLE CAUSES - Defective Compass/Mini-Trip Computer Incorrect Reading Beyond +/- 5 SYMPTOM * INCORRECT READING BEYOND +/- 5 POSSIBLE CAUSES - Defective Ambient Temperature Sensor Repairing OC In CMTC Display SYMPTOM * REPAIRING "OC" IN CMTC DISPLAY POSSIBLE CAUSES - Defective Ambient Temperature Sensor - SC - Defective CMTM/OC default - Open Ambient Temperature Sensor signal circuit - Open sensor ground circuit Repairing SC In CMTC Display SYMPTOM * REPAIRING "SC" IN CMTC DISPLAY POSSIBLE CAUSES - Ambient temperature sensor signal CKT-short/GND - Ambient temperature sensor signal CKT-sensor/GND - Defective ambient temperature sensor-OC - Defective CMTM/SC default Switch on Compass Mini-Trip Computer Inoperative SYMPTOM * SWITCH ON COMPASS MINI-TRIP COMPUTER INOPERATIVE TEST NOTE This symptom is diagnosed using the test * AVERAGE MPH/FUEL ECON INOPERATIVE OR WRONG. POSSIBLE CAUSES - Defective Compass/Mini-Trip computer Trip Odometer Inoperative/Wrong SYMPTOM * TRIP ODOMETER INOPERATIVE/WRONG Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Testing and Inspection > Reading and Clearing Diagnostic Trouble Codes > Page 250 TEST NOTE This symptom is diagnosed using the test * AVERAGE MPH/FUEL ECON INOPERATIVE OR WRONG. POSSIBLE CAUSES - Defective Compass/Mini-Trip computer Automatic (Rolling) Door Locks Inoperative SYMPTOM * AUTOMATIC (ROLLING) DOOR LOCKS INOPERATIVE POSSIBLE CAUSES - Link to body communication bus inoperative - Speed sensing door locks inoperative Doors Lock With Key In Ignition and Left Door Open SYMPTOM * DOORS LOCK WITH KEY IN IGNITION AND LEFT DOOR OPEN POSSIBLE CAUSES - Link to body communication bus inoperative - Ignition switch shorted - Key - in ignition switch sense circuit open - CTM input A9 short to ground - CTM input shorted to ground One or Both Doors Failing to Lock From One Switch SYMPTOM * ONE OR BOTH DOORS FAILING TO LOCK FROM ONE SWITCH POSSIBLE CAUSES - Link to body communication bus inoperative - Fused B (+) circuit open - Door lock actuator assembly defective - Door unlock actuator assembly defective - Door lock switch assembly open - Door unlock switch assembly open - Door lock driver circuit open - Door unlock driver circuit open - Door lock driver circuit open - Door unlock driver circuit open - Door unlock driver circuit open - Power door lock driver circuit open - CTM lock driver input open - CTM unlock driver input open - Lock driver circuit on CTM open - Unlock driver circuit on CTM open One or Both Doors Failing to Unlock From One Switch. SYMPTOM * ONE OR BOTH DOORS FAILING TO UNLOCK FROM ONE SWITCH TEST NOTE This symptom is diagnosed using the test * ONE OR BOTH DOORS FAILING TO LOCK FROM ONE SWITCH. POSSIBLE CAUSES - Link to body communication bus inoperative - Fused B (+) circuit open - Door lock actuator assembly defective - Door unlock actuator assembly defective - Door lock switch assembly open - Door unlock switch assembly open - Door lock driver circuit open - Door unlock driver circuit open Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Testing and Inspection > Reading and Clearing Diagnostic Trouble Codes > Page 251 - Door lock driver circuit open - Door unlock driver circuit open - Door unlock driver circuit open - Power door lock driver circuit open - CTM lock driver input open - CTM unlock driver input open - Lock driver circuit on CTM open - Unlock driver circuit on CTM open Remote Keyless Entry Problem SYMPTOM * REMOTE KEYLESS ENTRY PROBLEM POSSIBLE CAUSES - Link to body communication bus inoperative - Transmitter defective - CTM Defective - RKE function Intermittent Wipers Inoperative No DTCs - Regular Cab SYMPTOM * INTERMITTENT WIPERS INOPERATIVE NO DTCs POSSIBLE CAUSES - No response / CCD bus failure - CTM - Defective Multi-Function SW / 5.0 ohms - Open wiper park switch sense CKT - Defective wiper motor/12 volts - Defective Central Timer Module / stalk switch - Central Timer Module default / 12 volts - Open intermittent wiper mode sense CKT Intermittent Wipers to Work - Quad Cab SYMPTOM * INTERMITTENT WIPERS TO WORK POSSIBLE CAUSES - No response/CCD Bus Failure - CTM - Defective Multi-Function Switch / 5.0 Ohms - Open wiper park switch sense Circuit - Defective wiper motor / 12 volts - Defective Central Timer Module / Stalk switch - Central Timer Module default / 12 volts - Open intermittent wiper mode sense circuit Regular Cab SYMPTOM * NO WIPER ACTUATION AFTER WASH BUTTON PUSHED POSSIBLE CAUSES - CCD bus failure - no response CTM - Defective Central Timer Module / interval wiper times Quad Cab SYMPTOM * NO WIPER ACTUATION AFTER WASH BUTTON PUSHED POSSIBLE CAUSES - CCD bus failure-no response CTM - Open front washer switch sense CKT - Defective central timer module/washer pump Regular Cab SYMPTOM Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Testing and Inspection > Reading and Clearing Diagnostic Trouble Codes > Page 252 * WIPER SPEED SENSITIVE FEATURE INOPERATIVE POSSIBLE CAUSES - CCD bus failure - CTM - CCD bus failure - PCM - No response logic GND CKT open - No response B (+) CKT open - No response bus (-) CKT open - No response CTM DEF bus (-) CKT open - No response IGN SW RUN/ACCY CKT short - GND - No response IGN SW RUN/START CKT short - GND - No response power ground CKT open - Fuse # 6 defective - Fuse # 9 defective Quad Cab SYMPTOM * WIPER SPEED SENSITIVE FEATURE INOPERATIVE POSSIBLE CAUSES - CCD bus failure-CTM - CCD bus failure-PCM - Defective central timer module/interval wipes times Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Testing and Inspection > Reading and Clearing Diagnostic Trouble Codes > Page 253 Central Timer Module: Testing and Inspection Reading and Clearing Diagnostic Trouble Codes Diagnostic Trouble Code Descriptions For Information regarding diagnosis of all B, C, P, U and Manufacturer Codes See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions Diagnostic Trouble Code Tests and Associated Procedures For Information regarding diagnosis of all B, C, P, U and Manufacturer Codes See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures AM/FM Switch Inoperative SYMPTOM * AM/FM SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE. POSSIBLE CAUSES - Radio function controls inoperative Balance Dial Inoperative SYMPTOM * BALANCE DIAL INOPERATIVE TEST NOTE This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE. POSSIBLE CAUSES - Radio function controls inoperative CASS Error SYMPTOM CASS ERROR POSSIBLE CAUSES - Defective radio - CASS error CD Eject Switch Inoperative SYMPTOM * CD EJECT SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE. POSSIBLE CAUSES - Radio function controls inoperative CD Error SYMPTOM CD ERROR POSSIBLE CAUSES - Defective radio - CD error Equalizer Inoperative SYMPTOM * EQUALIZER INOPERATIVE Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Testing and Inspection > Reading and Clearing Diagnostic Trouble Codes > Page 254 TEST NOTE This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE. POSSIBLE CAUSES - Radio function controls inoperative External CD Changer (If Equipped) SYMPTOM * EXTERNAL CD CHANGER (IF EQUIPPED) POSSIBLE CAUSES - CD Cable assembly Defective - CD Changer Defective - Defective radio Fader Dial Inoperative SYMPTOM * FADER DIAL INOPERATIVE TEST NOTE This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE. POSSIBLE CAUSES - Radio function controls inoperative FF/RW Switch Inoperative SYMPTOM * FF/RW SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE. POSSIBLE CAUSES - Radio function controls inoperative Hour/Minute Switch Inoperative SYMPTOM * HOUR/MINUTE SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE. POSSIBLE CAUSES - Radio function controls inoperative No Sound From All Speakers SYMPTOM * NO SOUND FROM ALL SPEAKERS POSSIBLE CAUSES - Open radio choke output circuit - Open ground circuit - Open power antenna relay output CKT - radio / radio choke - Open radio 12v output circuit - Power antenna relay output CKT - short to ground - Defective radio - Defective radio choke relay No Sound From One Speaker SYMPTOM * NO SOUND FROM ONE SPEAKER Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Testing and Inspection > Reading and Clearing Diagnostic Trouble Codes > Page 255 POSSIBLE CAUSES - Speaker (-) circuit open - Rear speaker (+) circuit open - Rear speaker (-) circuit open - Defective front door speaker (+) INOP - Defective front door speaker (-) INOP - Front door speaker (+) circuit open - Front door speaker (-) circuit open - Front door speaker amp (+) faulty - Front door speaker amp (-) faulty - Front door speaker defective - Radio (+) defective - Radio (-) defective No Sound From Right/Left Side Speakers SYMPTOM * NO SOUND FROM RIGHT/LEFT SIDE SPEAKERS POSSIBLE CAUSES - Open ground circuit - Open radio choke output CKT - Radio DTC'S present - Defective front door speaker Pause/Play Switch Inoperative SYMPTOM * PAUSE/PLAY SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE. POSSIBLE CAUSES - Radio function controls inoperative Poor Sound Quality All Speakers SYMPTOM * POOR SOUND QUALITY ALL SPEAKERS POSSIBLE CAUSES - Antenna connector connection Defective - Ground circuit open - Radio choke output circuit Defective - Radio choke relay connection Defective - Power antenna relay CKT Defective - Radio connections Defective - Radio relay output Defective - Radio Defective Poor Sound Quality From One Speaker SYMPTOM * POOR SOUND QUALITY FROM ONE SPEAKER POSSIBLE CAUSES - Speaker (+) circuit open - Speaker (-) circuit open - Speaker defective - Radio (-) circuit defective - Door speaker defective - Radio (+) circuit defective PWR Switch Inoperative SYMPTOM Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Testing and Inspection > Reading and Clearing Diagnostic Trouble Codes > Page 256 * PWR SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE. POSSIBLE CAUSES - Radio function controls inoperative Radio Error SYMPTOM RADIO ERROR POSSIBLE CAUSES - Defective radio - radio error Remote Steering Wheel Switches (If Equipped) SYMPTOM * REMOTE STEERING WHEEL SWITCHES (IF EQUIPPED) POSSIBLE CAUSES - MUX control clockspring Defective - Radio control circuit Defective open - Radio control MUX circuit open - Radio control switch ground circuit open - Radio MUX Control circuit Defective - Remote control switch Defective - No response CCD bus failure - Central timer module Defective Scan Switch Inoperative SYMPTOM * SCAN SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE. POSSIBLE CAUSES - Radio function controls inoperative Seek Switch Inoperative SYMPTOM * SEEK SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE. POSSIBLE CAUSES - Radio function controls inoperative Set Switch Inoperative SYMPTOM * SET SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE. POSSIBLE CAUSES - Radio function controls inoperative Shorted Front Channel SYMPTOM SHORTED FRONT CHANNEL Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Testing and Inspection > Reading and Clearing Diagnostic Trouble Codes > Page 257 POSSIBLE CAUSES - Left front SPKR (+) circuit short to ground - Left front SPKR (-) circuit short to ground - Right front door speaker Defective - Right front SPKR (-) circuit short to ground - Left front door speaker Defective - Right front SPKR (+) circuit short to ground - Right rear speaker (+) CKT- short to ground - Right rear speaker (-) CKT- short to ground - Defective radio Shorted Left Channel SYMPTOM SHORTED LEFT CHANNEL POSSIBLE CAUSES - Left front door speaker defective - Left front SPKR (+) circuit short to ground - Left front SPKR (-) circuit short to ground - Left rear speaker (+) CKT- short to ground - Left rear speaker (-) CKT- short to ground - Defective radio Shorted Rear Channel SYMPTOM SHORTED REAR CHANNEL POSSIBLE CAUSES - Left front door speaker defective - Right front door speaker defective - Left rear speaker (+) CKT-short to ground - Left rear speaker (-) CKT-short to ground - Right rear speaker (+) CKT-short to ground - Right rear speaker (-) CKT-short to ground - Defective radio Shorted Right Channel SYMPTOM SHORTED RIGHT CHANNEL POSSIBLE CAUSES - Right front door speaker defective - Right front SPKR (+) circuit short to ground - Right front SPKR (-) circuit short to ground - Right rear speaker (+) CKT-short to ground - Right rear speaker (-) CKT-short to ground - Defective radio Tape Eject Switch Inoperative SYMPTOM * TAPE EJECT SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE. POSSIBLE CAUSES - Radio function controls inoperative Tune Switch Inoperative SYMPTOM * TUNE SWITCH INOPERATIVE Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Testing and Inspection > Reading and Clearing Diagnostic Trouble Codes > Page 258 TEST NOTE This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE. POSSIBLE CAUSES - Radio function controls inoperative Volume/Time Switch Inoperative SYMPTOM * VOL/TIME SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE. POSSIBLE CAUSES - Radio function controls inoperative 1-5 Presets Inoperative SYMPTOM * 1-5 PRESETS INOPERATIVE POSSIBLE CAUSES - Radio function controls inoperative Chime Inoperative - Engine Temperature Critical SYMPTOM * CHIME INOPERATIVE - ENGINE TEMPERATURE CRITICAL POSSIBLE CAUSES - Tone request circuit open - Instrument cluster tone request output defective - CTM fails chime test - PCM DTC coolant temp check Chime Inoperative - Key In Ignition & LF Door Open SYMPTOM * CHIME INOPERATIVE - KEY IN IGNITION & LF DOOR OPEN POSSIBLE CAUSES - Key in ignition switch sense ckt open - Ignition SW - key in switch open - CTM no chime to key in ignition - CTM not responding to key in switch Chime Inoperative at All Times SYMPTOM * CHIME INOPERATIVE AT ALL TIMES POSSIBLE CAUSES - CTM fails internal chime test Chime Inoperative With Exterior Lamps On SYMPTOM * CHIME INOPERATIVE WITH EXTERIOR LAMPS ON POSSIBLE CAUSES - Key in ignition switch sense circuit short to ground - Ignition SW - key in SW shorted - CTM - key in sense short default - Headlamp switch circuit open Chime Inoperative With Low Oil Pressure SYMPTOM Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Testing and Inspection > Reading and Clearing Diagnostic Trouble Codes > Page 259 * CHIME INOPERATIVE WITH LOW OIL PRESSURE POSSIBLE CAUSES - Oil pressure sender ground circuit open - Tone request circuit open - Instrument cluster - oil press Defective - CTM no response to oil pressure default - CTM fails chime test Chime Sounds With Driver Door Open SYMPTOM * CHIME SOUNDS WITH DRIVER DOOR OPEN POSSIBLE CAUSES - Key in ignition switch sense circuit short to ground - Ignition SW - key in SW shorted - CTM - key in sense short default - CTM not responding to key out Open Left Door Ajar Circuit SYMPTOM * OPEN LEFT DOOR AJAR CIRCUIT POSSIBLE CAUSES - Left front ajar switch sense circuit open - Left front door ajar switch sense circuit open - CTM defective - Left front door ajar switch defective, shorted Open Right Door Ajar Circuit SYMPTOM * OPEN RIGHT DOOR AJAR CIRCUIT POSSIBLE CAUSES - RF door ajar switch sense ground circuit open - Right front ajar switch sense circuit open - CTM defective - Right front door ajar switch defective, shorted Shorted Left Door Ajar Circuit SYMPTOM * SHORTED LEFT DOOR AJAR CIRCUIT POSSIBLE CAUSES - Central Timer Module defective - Left front door ajar switch defective, shorted - LF door ajar switch sense circuit short to GND Shorted Right Door Ajar Circuit SYMPTOM * SHORTED RIGHT DOOR AJAR CIRCUIT POSSIBLE CAUSES - RF door ajar switch sense circuit short to GND - CTM defective - Right front door ajar switch defective, shorted All Gauges Inoperative SYMPTOM * ALL GAUGES INOPERATIVE POSSIBLE CAUSES - Fused B (+) circuit from IOD fuse open Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Testing and Inspection > Reading and Clearing Diagnostic Trouble Codes > Page 260 - No response/CCD bus - Defective instrument cluster Any CCD Cluster Warning Lamp Inoperative SYMPTOM * ANY CCD CLUSTER WARNING LAMP INOPERATIVE POSSIBLE CAUSES - No response/CCD bus - CCD inoperative lamp/bulb defective - CCD lamp cluster input defective - CCD LP cluster test complete - Defective cluster - Instrument cluster defective Any Hard Wired Cluster Warning Lamp SYMPTOM * ANY HARD WIRED CLUSTER WARNING LAMP POSSIBLE CAUSES - Defective instrument cluster - Hard wired lamp circuit open - Inoperative lamp/bulb defective One Gauge Not Operating Properly SYMPTOM * ONE GAUGE NOT OPERATING PROPERLY POSSIBLE CAUSES - Gauge not reading 4 psi> engine warm at idle - Oil gauge not reading 4 psi or > at idle - Oil level low - Sensor ground circuit open - Instrument cluster circuit board defective - Oil pressure sensor defective - Charging system defective - Charging system DTC'S - Defective instrument cluster - Instrument cluster defective - Oil pressure sense circuit open - Oil pressure sense signal CKT short to ground - Cooling system operation faulty - Defective JTEC module - Fuel gauge inoperative - Instrument cluster defective - JTEC module defective - Oil pressure switch defective - Pinion factor incorrect - Powertrain Control Module defective Average MPH/Fuel Econ Inoperative or Wrong SYMPTOM * AVERAGE MPH/FUEL ECON INOPERATIVE OR WRONG POSSIBLE CAUSES - Defective Compass/Mini-Trip Computer CMTC Display Shows Failed SYMPTOM * CMTC DISPLAY SHOWS FAILED POSSIBLE CAUSES - Defective CMTC - display failed Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Testing and Inspection > Reading and Clearing Diagnostic Trouble Codes > Page 261 CMTC Fails to Respond to Instrument Panel Dimming SYMPTOM * CMTC FAILS TO RESPOND TO INSTRUMENT PANEL DIMMING TEST NOTE This symptom is diagnosed using the test * AVERAGE MPH/FUEL ECON INOPERATIVE OR WRONG. POSSIBLE CAUSES - Defective Compass/Mini-Trip Computer CMTC Segments Fail to Light Up SYMPTOM * CMTC SEGMENTS FAIL TO LIGHT UP POSSIBLE CAUSES - Defective Compass/Mini-Trip Computer - segments fail to light Distance to Empty Inoperative or Wrong SYMPTOM * DISTANCE TO EMPTY INOPERATIVE OR WRONG TEST NOTE This symptom is diagnosed using the test * AVERAGE MPH/FUEL ECON INOPERATIVE OR WRONG. POSSIBLE CAUSES - Defective Compass/Mini-Trip Computer Elapsed Time Inoperative/Wrong SYMPTOM *ELAPSED TIME INOPERATIVE/WRONG TEST NOTE This symptom is diagnosed using the test* AVERAGE MPH/FUEL ECON INOPERATIVE OR WRONG. POSSIBLE CAUSES - Defective Compass/Mini-Trip Computer Incorrect Reading Beyond +/- 5 SYMPTOM * INCORRECT READING BEYOND +/- 5 POSSIBLE CAUSES - Defective Ambient Temperature Sensor Repairing OC In CMTC Display SYMPTOM * REPAIRING "OC" IN CMTC DISPLAY POSSIBLE CAUSES - Defective Ambient Temperature Sensor - SC - Defective CMTM/OC default - Open Ambient Temperature Sensor signal circuit - Open sensor ground circuit Repairing SC In CMTC Display SYMPTOM * REPAIRING "SC" IN CMTC DISPLAY POSSIBLE CAUSES - Ambient temperature sensor signal CKT-short/GND - Ambient temperature sensor signal CKT-sensor/GND - Defective ambient temperature sensor-OC Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Testing and Inspection > Reading and Clearing Diagnostic Trouble Codes > Page 262 - Defective CMTM/SC default Switch on Compass Mini-Trip Computer Inoperative SYMPTOM * SWITCH ON COMPASS MINI-TRIP COMPUTER INOPERATIVE TEST NOTE This symptom is diagnosed using the test * AVERAGE MPH/FUEL ECON INOPERATIVE OR WRONG. POSSIBLE CAUSES - Defective Compass/Mini-Trip computer Trip Odometer Inoperative/Wrong SYMPTOM * TRIP ODOMETER INOPERATIVE/WRONG TEST NOTE This symptom is diagnosed using the test * AVERAGE MPH/FUEL ECON INOPERATIVE OR WRONG. POSSIBLE CAUSES - Defective Compass/Mini-Trip computer Automatic (Rolling) Door Locks Inoperative SYMPTOM * AUTOMATIC (ROLLING) DOOR LOCKS INOPERATIVE POSSIBLE CAUSES - Link to body communication bus inoperative - Speed sensing door locks inoperative Doors Lock With Key In Ignition and Left Door Open SYMPTOM * DOORS LOCK WITH KEY IN IGNITION AND LEFT DOOR OPEN POSSIBLE CAUSES - Link to body communication bus inoperative - Ignition switch shorted - Key - in ignition switch sense circuit open - CTM input A9 short to ground - CTM input shorted to ground One or Both Doors Failing to Lock From One Switch SYMPTOM * ONE OR BOTH DOORS FAILING TO LOCK FROM ONE SWITCH POSSIBLE CAUSES - Link to body communication bus inoperative - Fused B (+) circuit open - Door lock actuator assembly defective - Door unlock actuator assembly defective - Door lock switch assembly open - Door unlock switch assembly open - Door lock driver circuit open - Door unlock driver circuit open - Door lock driver circuit open - Door unlock driver circuit open - Door unlock driver circuit open - Power door lock driver circuit open - CTM lock driver input open - CTM unlock driver input open - Lock driver circuit on CTM open - Unlock driver circuit on CTM open Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Testing and Inspection > Reading and Clearing Diagnostic Trouble Codes > Page 263 One or Both Doors Failing to Unlock From One Switch. SYMPTOM * ONE OR BOTH DOORS FAILING TO UNLOCK FROM ONE SWITCH TEST NOTE This symptom is diagnosed using the test * ONE OR BOTH DOORS FAILING TO LOCK FROM ONE SWITCH. POSSIBLE CAUSES - Link to body communication bus inoperative - Fused B (+) circuit open - Door lock actuator assembly defective - Door unlock actuator assembly defective - Door lock switch assembly open - Door unlock switch assembly open - Door lock driver circuit open - Door unlock driver circuit open - Door lock driver circuit open - Door unlock driver circuit open - Door unlock driver circuit open - Power door lock driver circuit open - CTM lock driver input open - CTM unlock driver input open - Lock driver circuit on CTM open - Unlock driver circuit on CTM open Remote Keyless Entry Problem SYMPTOM * REMOTE KEYLESS ENTRY PROBLEM POSSIBLE CAUSES - Link to body communication bus inoperative - Transmitter defective - CTM Defective - RKE function Intermittent Wipers Inoperative No DTCs - Regular Cab SYMPTOM * INTERMITTENT WIPERS INOPERATIVE NO DTCs POSSIBLE CAUSES - No response / CCD bus failure - CTM - Defective Multi-Function SW / 5.0 ohms - Open wiper park switch sense CKT - Defective wiper motor/12 volts - Defective Central Timer Module / stalk switch - Central Timer Module default / 12 volts - Open intermittent wiper mode sense CKT Intermittent Wipers to Work - Quad Cab SYMPTOM * INTERMITTENT WIPERS TO WORK POSSIBLE CAUSES - No response/CCD Bus Failure - CTM - Defective Multi-Function Switch / 5.0 Ohms - Open wiper park switch sense Circuit - Defective wiper motor / 12 volts - Defective Central Timer Module / Stalk switch - Central Timer Module default / 12 volts - Open intermittent wiper mode sense circuit Regular Cab SYMPTOM Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Testing and Inspection > Reading and Clearing Diagnostic Trouble Codes > Page 264 * NO WIPER ACTUATION AFTER WASH BUTTON PUSHED POSSIBLE CAUSES - CCD bus failure - no response CTM - Defective Central Timer Module / interval wiper times Quad Cab SYMPTOM * NO WIPER ACTUATION AFTER WASH BUTTON PUSHED POSSIBLE CAUSES - CCD bus failure-no response CTM - Open front washer switch sense CKT - Defective central timer module/washer pump Regular Cab SYMPTOM * WIPER SPEED SENSITIVE FEATURE INOPERATIVE POSSIBLE CAUSES - CCD bus failure - CTM - CCD bus failure - PCM - No response logic GND CKT open - No response B (+) CKT open - No response bus (-) CKT open - No response CTM DEF bus (-) CKT open - No response IGN SW RUN/ACCY CKT short - GND - No response IGN SW RUN/START CKT short - GND - No response power ground CKT open - Fuse # 6 defective - Fuse # 9 defective Quad Cab SYMPTOM * WIPER SPEED SENSITIVE FEATURE INOPERATIVE POSSIBLE CAUSES - CCD bus failure-CTM - CCD bus failure-PCM - Defective central timer module/interval wipes times Component Tests and General Diagnostics Some complaints will require a test drive as part of the repair verification procedure. The purpose of the test drive is to try to duplicate the diagnostic code or symptom condition. CAUTION: BEFORE ROAD TESTING A VEHICLE, BE SURE THAT ALL COMPONENTS ARE REASSEMBLED. DURING THE TEST DRIVE, DO NOT TRY TO READ THE DRB SCREEN WHILE IN MOTION.DO NOT HANG THE DRB FROM THE REAR VIEW MIRROR OR OPERATE IT YOURSELF. HAVE AN ASSISTANT AVAILABLE TO OPERATE THE DRB. Regular Cab DRB III ERROR MESSAGES AND BLANK SCREEN Under normal operation, the DRB will display one of only two error messages: -User-Requested WARM Boot or User- Requested COLD Boot If the DRB should display any other error message, record the entire display and call the MDS Hotline, or call for information and assistance at 1-800-825-8737.This is a sample of such an error message display: ver: 2.14 date: 26 Jul93 file: key_itf.cc date: Jul 26 1993 line: 548 err: Ox1 User-Requested COLD Boot Press MORE to switch between this display and the application screen. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Testing and Inspection > Reading and Clearing Diagnostic Trouble Codes > Page 265 Press F4 when done noting information. DRB III does not power up (blank screen) If the LED's do not light or no sound is emitted at start up, check for loose cable connections or a bad cable. Check the vehicle battery voltage (data link connector cavity 16). A minimum of 11 volts is required to adequately power the DRB. If all connections are proper between the DRB and the vehicle or other devices, and the vehicle battery is fully charged, an inoperative DRB may be the result of faulty cable or vehicle wiring. DRB III Display is not visible Low temperatures will affect the visibility of the display. Adjust the contrast to compensate for this condition. Quad Cab Under normal operation, the DRB will display one of only two error messages: - User-Requested WARM Boot or User-Requested COLD Boot. If the DRB should display any other error message, record the entire display and call the MDS Hotline, or call for information and assistance at 1-800-825-8737. This is a sample of such an error message display: Ver: 2.4 date: 26 Jul93 file: key_itf.cc date: Jul 26 993 line: 548 err: Ox1 User-Requested COLD Boot Press MORE to switch between this display and the application screen. Press F4 when done noting information. DRB III does not power up (Blank Screen) If the LED's do not light or no sound is emitted at start up, check for loose cable connections or a bad cable. Check the vehicle battery voltage (data link connector cavity 6). A minimum of volts is required to adequately power the DRB. If all connections are proper between the DRB and the vehicle or other devices, and the vehicle battery is fully charged, an inoperative DRB may be the result of faulty cable or vehicle wiring. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Testing and Inspection > Reading and Clearing Diagnostic Trouble Codes > Page 266 DRB III Display is not visible Low temperatures will affect the visibility of the display. Adjust the contrast to compensate for this condition. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Testing and Inspection > Page 267 Central Timer Module: Tools and Equipment DRB III (diagnostic read-out box) Jumper Wires Ohmmeter Voltmeter Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest: > 18-15-00 > Sep > 00 > ECM - Poor Driveability/Hard Engine Restart Powertrain Control Module: Customer Interest ECM - Poor Driveability/Hard Engine Restart NUMBER: 18-15-00 GROUP: Vehicle Performance DATE: Sept. 8, 2000 SUBJECT: Driveability Enhancements With Winter Fuel Use And For Hard Hot Engine Restarts 0VERVIEW: This bulletin involves selectively erasing and reprogramming the Cummins CM551 Engine Control Module (ECM) with new software (calibration versions: 57T11A, 5711B, 56T13). There is no change to the JTEC PCM software. MODELS: 1999 - 2001 (BR/BE) Ram Truck NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 5.9L-24V DIESEL ENGINE BUILT ON OR BETWEEN ENGINE SERIAL NUMBERS 56478845 TO 56744082, WITH A DATE OF MANUFACTURE OF JULY 8, 1998 TO JUNE 29, 2000. THIS INFORMATION IS AVAILABLE ON THE ENGINE DATA PLATE, WHICH IS LOCATED ON THE LEFT SIDE OF THE ENGINE, AFFIXED TO THE GEAR HOUSING. SYMPTOM/CONDITION: The customer may complain of poor driveability when winter fuel is used to power the engine. The customer may complain of a no start or a hard hot engine restart condition when using any type of good quality diesel fuel. The poor driveability condition may occur only when either straight # 1 diesel fuel is used or when other special cold climate winter blend fuels are in use. The no start or long engine crank condition may occur when attempting to restart the engine while the temperature of the engine is still close to its normal operating temperature. This hard hot restart condition may be experienced in all ambient climates, but may be more of a concern in warmer ambient climates. DIAGNOSIS: Using the Mopar Diagnostic System (MDS2) and or the Diagnostic Scan Tool (DRB III(R), with the appropriate Diagnostic Procedures Manual, verify that all engine and transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If no DIC's are present, and the above symptom has been experienced, perform the Repair Procedure. NOTE: WHENEVER AN ENGINE CONTROL MODULE (ECM) IS REPLACED DUE TO FAILURE, THE SOFTWARE OF THE REPLACEMENT CONTROLLER MUST BE VERIFIED FOR THE LATEST REVISION LEVEL. USE THE FLASH PROCEDURE TO UPDATE REPLACED CONTROLLERS AS NECESSARY. PARTS REQUIRED: EQUIPMENT REQUIRED: NOTE: THE MDS2 AND DRB III(R) ARE REQUIRED TO PERFORM PART OF THIS REPAIR. WHEN USING THE MDS2 AND THE DRB III(R), THE SYSTEM MUST BE OPERATING AT CIS CD 2066 OR HIGHER. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest: > 18-15-00 > Sep > 00 > ECM - Poor Driveability/Hard Engine Restart > Page 276 REPAIR PROCEDURE: 1. Log onto the MDS2 system. 2. Connect the MDS2 and DRB III(R) to the vehicle and switch the ignition key to "ON". 3. Use the arrow keys and select # 2 CONNECT TO MDS2 on the DRB III(R) MAIN MENU SCREEN. 4. Use the arrow keys and select # 2 RUN MDS2 APPLICATION on the DRB III(R) MAIN MENU SCREEN. NOTE: ONCE MDS2, DRB III(R), AND VEHICLE COMMUNICATION HAS BEEN ESTABLISHED, THE "CANNOT READ VIN FROM DRB III(R)" MESSAGE (ON THE MDS2) WILL BE REPLACED BY THE VEHICLE VIN. PRESS THE "OK" BUTTON ON THE MDS2 TO REQUEST A MDS2 SESSION FOR THE VEHICLE VIN INDICATED. PRESS THE "OK" BUTTON WHEN ASKED TO BEGIN SESSION. 5. Select the FLASH tab on the MDS2. 6. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. Press the "OK" button. NOTE: IN ABOVE STEPS # 5 AND/OR # 6, A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION. 7. Select the new software part number with the light pen and click UPDATE CONTROLLER SOFTWARE. 8. The MDS2 and DRB III(R) will prompt for any operator action needed during the remainder of the reprogramming process. NOTE: DUE TO THE ECM REPROGRAMMING PROCEDURE, A DTC MAY BE SET IN OTHER MODULES (PCM, BCM, MIC, SKIM, ETC.) WITHIN THE VEHICLE IF SO EQUIPPED. SOME DTC'S MAY CAUSE THE MIL TO ILLUMINATE. ALL DTC'S RELATE TO A LOSS OF COMMUNICATIONS WITH THE MODULE THAT IS BEING REPROGRAMMED. CHECK ALL MODULES, RECORD THE FAULTS, AND ERASE THESE FAULTS PRIOR TO RETURNING THE VEHICLE TO THE CUSTOMER. ERASE ANY FAULTS IN THE PCM ONLY AFTER ALL OTHER MODULES HAVE HAD THEIR FAULTS ERASED. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. 9. Type the necessary information on the "Authorized Software Update Label" pin 04669020 (Figure 1). Attach the label to the CUMMINS ECM and cover the label with the clear plastic overlay. Do not attach the label to the JTEC PCM. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest: > 18-15-00 > Sep > 00 > ECM - Poor Driveability/Hard Engine Restart > Page 277 10. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI label (Figure 2). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: FM - Flash Module Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest: > 21-01-00 > Feb > 00 > A/T - Harsh Reverse Gear Engagement Powertrain Control Module: Customer Interest A/T - Harsh Reverse Gear Engagement NUMBER: 21-01-00 GROUP: Transmission DATE: Feb 4, 2000 SUBJECT: Intermittent Harsh Engagement Into Reverse Gear On Certain RE Model Transmissions OVERVIEW: This bulletin involves the replacement of the transmission valve body upper housing separator plate and a valve body check ball. In addition, for 2000 M.Y. vehicles equipped with a 46RE transmission this bulletin involves selectively erasing and reprogramming the JTEC Powertrain Control Module (PCM) with new software (calibration change 00Cal13/13A). MODELS: 2000 (AB) Ram Van 1999 - 2000 (AN) Dakota 1999 - 2000 (BR/BE) Ram Truck 2000 (DN) Durango 1999 - 2000 (WJ) Grand Cherokee NOTE: THIS INFORMATION APPLIES TO 1999 AND 2000 MODEL YEAR VEHICLES EQUIPPED WITH EITHER A 42RE AUTOMATIC TRANSMISSION BUILT BEFORE SEPTEMBER 1, 1999 (MDH 0901 XX) OR 2000 MODEL YEAR VEHICLES EQUIPPED WITH A 46RE AUTOMATIC TRANSMISSION BUILT BEFORE DECEMBER 1,1999 (MDH I2OIXX). SYMPTOM/CONDITION: The customer may experience a harsh engagement into gear when reverse is selected. This condition may be intermittent, and may occur more frequently as the transmission fluid warms to normal operating temperatures. DIAGNOSIS: 1. Verify that the transmission fluid level is correct. 2. Verify that the valve body throttle valve and transmission shift linkage is adjusted properly. Using the Mopar Diagnostic System (MDS2) and or the Diagnostic Scan Tool (DRB III) with the appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If no DTC's are present, and the above symptoms have been experienced, perform the Repair Procedure. NOTE: WHENEVER A POWERTRAIN CONTROL MODULE (PCM) IS REPLACED DUE TO FAILURE, THE SOFTWARE OF THE REPLACEMENT CONTROLLER MUST BE VERIFIED FOR THE LATEST REVISION LEVEL. USE THE FLASH PROCEDURE TO UPDATE REPLACED CONTROLLERS AS NECESSARY. EQUIPMENT REQUIRED: 1 CH6OOO Scan Tool (DRB III) 1 CH7035 General Purpose Interface Bus Cable (GPIB) 1 CH700017001 J1962 Cable 1 MDS2 NOTE: THE MDS2 AND DRB III ARE REQUIRED TO PERFORM PART OF THIS REPAIR. WHEN USING THE MDS2 AND THE DRB III, THE SYSTEM MUST BE OPERATING AT CIS CD 2051 OR HIGHER. PARTS REQUIRED: 1 52118261 Ball, Rear Servo Check ('Torlon" - plastic for 42RE and 46RE) 1 52118272 Plate, Valve Body Separator (42RE trans.) 1 04295875 Gasket, Transmission Pan (42RE trans.) 1 04617196AB Plate, Valve Body Separator (46RE trans.) 1 05012978AA Gasket, Transmission Pan (46RE trans.) 10 05010124AA Fluid, Transmission ATF +3 1(AR) 04669020 Label, Authorized Software Update (if a 46RE trans.) 1(AR) 04275086 Label, Authorized Modification (if a 46RE trans.) Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest: > 21-01-00 > Feb > 00 > A/T - Harsh Reverse Gear Engagement > Page 282 REPAIR PROCEDURE: For both the 1999 and 2000 M.Y. 42RE and 46RE Transmission: 1. Refer to the appropriate year information on Transmission and Transfer Case removal and installation instructions of the transmission valve body, check ball, upper housing separator plate, and pan gasket. 2. Replace the original steel rear servo check ball with the plastic "Torlon" check ball (p/n 52118261). 3. Clean the new separator plate to remove any dirt or rust inhibitor prior to installation. 4. Install the new transmission valve body upper housing separator plate (p/n 52118272 or p/n 04617196AB). 5. Reassemble the transmission. 6. Install a new transmission pan gasket (p/n 04295875 or p/n 05012978AA). 7. Lower vehicle and install transmission fluid (p/n 05010124AA). 8. Verify fluid level after warming up the transmission and cycling the shift lever several times. 9. Verify, and if required, adjust the transmission shift linkage and the transmission throttle valve cable per the appropriate Service Manual procedures. For the 2000 M.Y. 46RE Transmission Only: 1. Log onto the MDS2 system. 2. Connect the MDS2 (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and switch the ignition key to "ON". 3. Use the arrow keys and select # 2 CONNECT TO MDS2 on the DRB III MAIN MENU SCREEN. 4. Use the arrow keys and select # 2 RUN MDS2 APPLICATION on the DRB III MAIN MENU SCREEN. NOTE: ONCE MDS2, DRB III, AND VEHICLE COMMUNICATION HAS BEEN ESTABLISHED, THE "CANNOT READ VIN FROM DRB III "MESSAGE (ON THE MDS) WILL BE REPLACED BY THE VEHICLE VIN. PRESS THE "OK" BUTTON ON THE MDS2 TO REQUEST A MDS2 SESSION FOR THE VEHICLE VIN INDICATED. PRESS THE "OK" BUTTON WHEN ASKED TO BEGIN SESSION. 5. Push the FLASH tab on the MDS2. NOTE: A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION. 6. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. NOTE: A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION. 7. Select the new software part number with the light pen and click UPDATE CONTROLLER SOFTWARE. 8. The MDS2 and DRB III will prompt for any operator action needed during the remainder of the reprogramming process. NOTE: DUE TO THE PCM FLASH PROCEDURE, A DTC MAY BE SET IN OTHER MODULES (EATX, BCM, MIC, SKIM, ABS) WITHIN THE VEHICLE IF SO EQUIPPED. SOME MAY CAUSE THE MIL TO ILLUMINATE. ALL DTC'S RELATE TO A LOSS OF COMMUNICATIONS WITH THE MODULE THAT IS BEING FLASHED. CHECK ALL MODULES, RECORD THE FAULTS, AND ERASE THESE FAULTS PRIOR TO RETURNING THE VEHICLE TO THE CUSTOMER. ERASE ANY FAULTS IN THE PCM ONLY AFTER ALL OTHER MODULES HAVE HAD THEIR FAULTS ERASED. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest: > 21-01-00 > Feb > 00 > A/T - Harsh Reverse Gear Engagement > Page 283 Fig. 1 9. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Figure 1). Attach the label to the JTEC PCM and cover the label with the clear plastic overlay. Fig. 2 10. Type the necessary information on the "Authorized Modification Label" pin 04275086 and attach the label near the VECI label (Figure 2). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 21-95-01-93 Valve Body, Check Ball and Plate - Replace 1.7 Hrs. 1999-2000 (AB, AN, BR, BE, DN, WJ) 08-19-42-94 Powertrain Control Module - Reprogram (46RE only) 0.5 Hrs. 2000 (AN, AB, BR, BE, DN) FAILURE CODE: P8- New Part FM - Flash Module Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 18-033-04 > Aug > 04 > Engine Controls - Generic Engine Module Programming Powertrain Control Module: All Technical Service Bulletins Engine Controls - Generic Engine Module Programming NUMBER: 18-033-04 GROUP: Vehicle Performance DATE: August 20, 2004 THE DRBIII(R) FLASH FILES FOR THIS BULLETIN ARE AVAILABLE ON DealerCONNECT. FOR MARKETS OUTSIDE OF THE UNITED STATES AND CANADA, THE FLASH FILES AND REPROGRAMMING INSTRUCTIONS WILL BE AVAILABLE ON ITIL/ISIS DVD OCTOBER, 2004. THIS BULLETIN SUPERSEDES SERVICE BULLETIN 18-030-03 REV. A DATED OCTOBER 17, 2003, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES 8 ADDITIONAL PART NUMBERS, AN ADDITIONAL MODEL YEAR, AND AN UPDATED REPAIR PROCEDURE. SUBJECT: Generic Cummins Engine Control Module (ECM) Procedure OVERVIEW: This bulletin involves programming a generic Cummins ECM with software. MODELS NOTE: This bulletin applies to Ram trucks equipped with the 5.9L Cummins 24-valve diesel engine (sales code ETC or ETH). DISCUSSION: Mopar(R) is phasing out pre-programmed Cummins Diesel Engine Control Modules (ECM). New modules will no longer be pre-programmed when received from Mopar(R). Replacement of future ECM's will require programming utilizing the DRBIII(R) and TechCONNECT. 1998 1/2 - 2002 modules will cause the "Wait to Start" light to flash, indicating the module has not been programmed. CAUTION: Extreme care must be taken when programming the flash file of a generic ECM. Do not randomly select a flash file. If in doubt, contact the STAR Center for assistance. Installing an incorrect flash file into an ECM can cause severe engine damage. Once a flash file is selected and programmed, the controller cannot be reprogrammed with a different flash file. The module can only be reprogrammed to a more recent version of the same released flash file. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 18-033-04 > Aug > 04 > Engine Controls - Generic Engine Module Programming > Page 289 PARTS REQUIRED Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 18-033-04 > Aug > 04 > Engine Controls - Generic Engine Module Programming > Page 290 SPECIAL TOOLS/EQUIPMENT REQUIRED: NOTE: An updated J1962 cable has been released. This cable has a red colored connector at the DRBIII(R) connection. Use this cable whenever a flash is being performed. REPAIR PROCEDURE: NOTE: Whenever a controller is programmed, the software in the DRBIII(R) must be programmed with the latest revision level available. NOTE: If this flash process is interrupted/aborted, the flash process should be restarted and then follow the directions on the DRBIII(R). 1. Before beginning the reprogramming procedure, remove any old flash reprogramming files from the DRBIII(R) memory. To clear the memory from the MAIN MENU power up the DRBIII(R) and then: a. Simultaneously press the "MORE" and "YES" keys. b. A screen will appear requesting a "COLD BOOT". c. Follow the on screen instructions by selecting the "F4" key. d. When the DRBIII(R) reboots to the MAIN MENU, proceed to Step # 2. 2. With the ignition switch in the "RUN" position, determine and record the "ECM part number" of the ECM currently in the vehicle. Using the DRBIII(R) select: a. "DRBIII(R) Standalone" b. "1998 - 2005 Diagnostics" c. "All (Except Below)" d. "Engine" e. On 1998 1/2 - 2003 vehicles, select "Cummins". 2004 and later vehicles, proceed to next step. f. "Module Display" g. Record the "ECM part number" on the repair order for later reference. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 18-033-04 > Aug > 04 > Engine Controls - Generic Engine Module Programming > Page 291 NOTE: If the ECM is not operational, the "ECM part number" can be obtained from the label on the controller. For 1998 1/2 - 2002 vehicles, if the label on the controller is not legible, proceed to next step. For 2003 and later vehicles, if the label on the controller is not legible, record the "Reference No." for use later. The "Reference No." is located in the Reference No. box at the top, center of the Engine Data Plate (Fig. 1). Do not use the reference number shown in the figure. The Engine Data Plate is located on the intake side of the breather cover or affixed to the APPS bracket. 3. Page back to the "Main Menu" 4. Determine if the vehicle is equipped with SKIM. Using the DRBIII(R) select: a. "DRBIII Standalone" b. "1998 - 2005 Diagnostics" c. "All" d. "System Monitor" e. "J1850 Module Scan" f. Look for "SKIM" in the list of modules. 5. If the vehicle is not equipped with SKIM then proceed to Step # 6. If the vehicle is equipped with SKIM obtain the vehicle Personal Identification Number (PIN) before continuing with Step # 6. This information is available from: a. The original selling invoice. b. The DealerCONNECT system under the "Sales" or "Parts" tabs - select "Key Codes". c. By contacting the District Manager. CAUTION: Failure to install the SKIM pin number into the module after flashing the Cummins ECM will cause a start and stall condition. 6. Open the hood, install a battery charger and verify that the charging rate provides approximately 13.5 volts. 7. If the old "ECM part number" is known, or for 2003 and later vehicles, proceed to Step # 14. On 1998 1/2 - 2002 vehicles, if the old "ECM part number" is not known, proceed to next step. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 18-033-04 > Aug > 04 > Engine Controls - Generic Engine Module Programming > Page 292 8. On DealerCONNECT select the "Service" tab. 9. Select "Vehicle Information Plus". 10. Select "Single VIN Inquiry". 11. Manually enter the VIN and mileage and select "Enter". 12. Select the "Vehicle Option" tab. 13. Under the "Vehicle Option" window, identify and record: a. Engine (sales code and description). b. Emissions (Federal or California) c. Transmission (Automatic, 5-speed manual, etc.). NOTE: When reprogramming a Cummins ECM be sure to do the following; ^ Download the flash file from TechCONNECT to the DRBIII(R) with the DRBIII(R) disconnected from the vehicle. ^ Download the flash file from the DRBIII(R) to the vehicle with the DRBIII(R) disconnected from TechCONNECT. 14. Connect the DRBIII(R) to TechCONNECT. Open TechTOOLS and verify that the "DRBIII(R) Status: Connected" message is in the upper right corner of the TechTOOLS screen. 15. Enter the old Cummins "ECM part number" obtained from the DRBIII(R) in Step # 2 into the "Parts Criteria" window. 16. Select "Show Updates". 17. Highlight the proper flash file from the list: a. If the old "ECM part number" is known, highlight the flash file listed, based on the old "ECM part number" recorded earlier Step # 2. b. For 1998 1/2 - 2002, if the old "ECM part number" is not known, highlight the correct flash file based on the information that was recorded from "Vehicle Options" Step # 13. c. For 2003 and later, if the old part number is not known, highlight the proper flash file based on the Reference No. located in the "Ref. No." box, at the top, center of the Engine Data Plate (Fig. 1). 18. Select the "DRBIII" radio button which is next to the "Download/Update" button. 19. Select the "Download/Update" button. 20. Monitor the "Flash Download/Update Progress" window on the TechCONNECT and follow the instructions on TechCONNECT. When the flash process is complete, proceed to the next step. 21. Disconnect the DRBIII(R) from TechCONNECT. 22. Connect the DRBIII(R) to the vehicle. 23. Download the flash file from the DRBIII(R) to the vehicle. Using the DRBIII(R) select: a. "Vehicle Flash" b. Follow the directions on the DRBIII(R) screen. When the flash process is complete, proceed to the next step. 24. If the vehicle is equipped with SKIM, proceed to Step # 25. If the vehicle is not equipped with SKIM, proceed to Step # 26. 25. On vehicles equipped with SKIM, transfer the VIN and Security Key information from the SKIM to the ECM. Using the DRBIII(R) select: a. "DRBIII Standalone" Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 18-033-04 > Aug > 04 > Engine Controls - Generic Engine Module Programming > Page 293 b. "1998 - 2005 Diagnostics" c. "All" d. "TheftAlarm" e. "SKIM" f. "Miscellaneous" g. "Cummins ECM Replaced" h. Follow the directions on the DRBIII(R) screen. When the process is complete, proceed to Step # 27. 26. On vehicles not equipped with SKIM, manually enter the VIN in the ECM. Using the DRBIII(R) select: a. "DRBIII Standalone" b. "1998 - 2005 Diagnostics" c. "All" d. "Engine" e. "Cummins Controller (ECM/ENGINE)" f. "Miscellaneous" g. "CM84X Check VIN" h. Follow the directions on the DRBIII(R) screen. When the process is complete, proceed to next step. NOTE: Due to the Cummins controller programming procedure, a DTC may be set in other modules (PCM, TCM, BCM, MIC, SKIM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. Check all modules using "Module Scan", record the DTC's, and erase these DTC's prior to returning the vehicle to the customer. Erase any DTC's in the PCM only after all other modules have had their DTC's erased. NOTE: The following step is required by law. 27. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label (Fig. 2). POLICY: Reimbursable within the provisions of the warranty. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 18-033-04 > Aug > 04 > Engine Controls - Generic Engine Module Programming > Page 294 TIME ALLOWANCE: Refer to Quick Labor Operations or the appropriate Labor Operation Time Schedule manual. Disclaimer This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 18-15-00 > Sep > 00 > ECM Poor Driveability/Hard Engine Restart Powertrain Control Module: All Technical Service Bulletins ECM - Poor Driveability/Hard Engine Restart NUMBER: 18-15-00 GROUP: Vehicle Performance DATE: Sept. 8, 2000 SUBJECT: Driveability Enhancements With Winter Fuel Use And For Hard Hot Engine Restarts 0VERVIEW: This bulletin involves selectively erasing and reprogramming the Cummins CM551 Engine Control Module (ECM) with new software (calibration versions: 57T11A, 5711B, 56T13). There is no change to the JTEC PCM software. MODELS: 1999 - 2001 (BR/BE) Ram Truck NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 5.9L-24V DIESEL ENGINE BUILT ON OR BETWEEN ENGINE SERIAL NUMBERS 56478845 TO 56744082, WITH A DATE OF MANUFACTURE OF JULY 8, 1998 TO JUNE 29, 2000. THIS INFORMATION IS AVAILABLE ON THE ENGINE DATA PLATE, WHICH IS LOCATED ON THE LEFT SIDE OF THE ENGINE, AFFIXED TO THE GEAR HOUSING. SYMPTOM/CONDITION: The customer may complain of poor driveability when winter fuel is used to power the engine. The customer may complain of a no start or a hard hot engine restart condition when using any type of good quality diesel fuel. The poor driveability condition may occur only when either straight # 1 diesel fuel is used or when other special cold climate winter blend fuels are in use. The no start or long engine crank condition may occur when attempting to restart the engine while the temperature of the engine is still close to its normal operating temperature. This hard hot restart condition may be experienced in all ambient climates, but may be more of a concern in warmer ambient climates. DIAGNOSIS: Using the Mopar Diagnostic System (MDS2) and or the Diagnostic Scan Tool (DRB III(R), with the appropriate Diagnostic Procedures Manual, verify that all engine and transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If no DIC's are present, and the above symptom has been experienced, perform the Repair Procedure. NOTE: WHENEVER AN ENGINE CONTROL MODULE (ECM) IS REPLACED DUE TO FAILURE, THE SOFTWARE OF THE REPLACEMENT CONTROLLER MUST BE VERIFIED FOR THE LATEST REVISION LEVEL. USE THE FLASH PROCEDURE TO UPDATE REPLACED CONTROLLERS AS NECESSARY. PARTS REQUIRED: EQUIPMENT REQUIRED: NOTE: THE MDS2 AND DRB III(R) ARE REQUIRED TO PERFORM PART OF THIS REPAIR. WHEN USING THE MDS2 AND THE DRB III(R), THE SYSTEM MUST BE OPERATING AT CIS CD 2066 OR HIGHER. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 18-15-00 > Sep > 00 > ECM Poor Driveability/Hard Engine Restart > Page 299 REPAIR PROCEDURE: 1. Log onto the MDS2 system. 2. Connect the MDS2 and DRB III(R) to the vehicle and switch the ignition key to "ON". 3. Use the arrow keys and select # 2 CONNECT TO MDS2 on the DRB III(R) MAIN MENU SCREEN. 4. Use the arrow keys and select # 2 RUN MDS2 APPLICATION on the DRB III(R) MAIN MENU SCREEN. NOTE: ONCE MDS2, DRB III(R), AND VEHICLE COMMUNICATION HAS BEEN ESTABLISHED, THE "CANNOT READ VIN FROM DRB III(R)" MESSAGE (ON THE MDS2) WILL BE REPLACED BY THE VEHICLE VIN. PRESS THE "OK" BUTTON ON THE MDS2 TO REQUEST A MDS2 SESSION FOR THE VEHICLE VIN INDICATED. PRESS THE "OK" BUTTON WHEN ASKED TO BEGIN SESSION. 5. Select the FLASH tab on the MDS2. 6. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. Press the "OK" button. NOTE: IN ABOVE STEPS # 5 AND/OR # 6, A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION. 7. Select the new software part number with the light pen and click UPDATE CONTROLLER SOFTWARE. 8. The MDS2 and DRB III(R) will prompt for any operator action needed during the remainder of the reprogramming process. NOTE: DUE TO THE ECM REPROGRAMMING PROCEDURE, A DTC MAY BE SET IN OTHER MODULES (PCM, BCM, MIC, SKIM, ETC.) WITHIN THE VEHICLE IF SO EQUIPPED. SOME DTC'S MAY CAUSE THE MIL TO ILLUMINATE. ALL DTC'S RELATE TO A LOSS OF COMMUNICATIONS WITH THE MODULE THAT IS BEING REPROGRAMMED. CHECK ALL MODULES, RECORD THE FAULTS, AND ERASE THESE FAULTS PRIOR TO RETURNING THE VEHICLE TO THE CUSTOMER. ERASE ANY FAULTS IN THE PCM ONLY AFTER ALL OTHER MODULES HAVE HAD THEIR FAULTS ERASED. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. 9. Type the necessary information on the "Authorized Software Update Label" pin 04669020 (Figure 1). Attach the label to the CUMMINS ECM and cover the label with the clear plastic overlay. Do not attach the label to the JTEC PCM. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 18-15-00 > Sep > 00 > ECM Poor Driveability/Hard Engine Restart > Page 300 10. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI label (Figure 2). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: FM - Flash Module Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 21-01-00 > Feb > 00 > A/T Harsh Reverse Gear Engagement Powertrain Control Module: All Technical Service Bulletins A/T - Harsh Reverse Gear Engagement NUMBER: 21-01-00 GROUP: Transmission DATE: Feb 4, 2000 SUBJECT: Intermittent Harsh Engagement Into Reverse Gear On Certain RE Model Transmissions OVERVIEW: This bulletin involves the replacement of the transmission valve body upper housing separator plate and a valve body check ball. In addition, for 2000 M.Y. vehicles equipped with a 46RE transmission this bulletin involves selectively erasing and reprogramming the JTEC Powertrain Control Module (PCM) with new software (calibration change 00Cal13/13A). MODELS: 2000 (AB) Ram Van 1999 - 2000 (AN) Dakota 1999 - 2000 (BR/BE) Ram Truck 2000 (DN) Durango 1999 - 2000 (WJ) Grand Cherokee NOTE: THIS INFORMATION APPLIES TO 1999 AND 2000 MODEL YEAR VEHICLES EQUIPPED WITH EITHER A 42RE AUTOMATIC TRANSMISSION BUILT BEFORE SEPTEMBER 1, 1999 (MDH 0901 XX) OR 2000 MODEL YEAR VEHICLES EQUIPPED WITH A 46RE AUTOMATIC TRANSMISSION BUILT BEFORE DECEMBER 1,1999 (MDH I2OIXX). SYMPTOM/CONDITION: The customer may experience a harsh engagement into gear when reverse is selected. This condition may be intermittent, and may occur more frequently as the transmission fluid warms to normal operating temperatures. DIAGNOSIS: 1. Verify that the transmission fluid level is correct. 2. Verify that the valve body throttle valve and transmission shift linkage is adjusted properly. Using the Mopar Diagnostic System (MDS2) and or the Diagnostic Scan Tool (DRB III) with the appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If no DTC's are present, and the above symptoms have been experienced, perform the Repair Procedure. NOTE: WHENEVER A POWERTRAIN CONTROL MODULE (PCM) IS REPLACED DUE TO FAILURE, THE SOFTWARE OF THE REPLACEMENT CONTROLLER MUST BE VERIFIED FOR THE LATEST REVISION LEVEL. USE THE FLASH PROCEDURE TO UPDATE REPLACED CONTROLLERS AS NECESSARY. EQUIPMENT REQUIRED: 1 CH6OOO Scan Tool (DRB III) 1 CH7035 General Purpose Interface Bus Cable (GPIB) 1 CH700017001 J1962 Cable 1 MDS2 NOTE: THE MDS2 AND DRB III ARE REQUIRED TO PERFORM PART OF THIS REPAIR. WHEN USING THE MDS2 AND THE DRB III, THE SYSTEM MUST BE OPERATING AT CIS CD 2051 OR HIGHER. PARTS REQUIRED: 1 52118261 Ball, Rear Servo Check ('Torlon" - plastic for 42RE and 46RE) 1 52118272 Plate, Valve Body Separator (42RE trans.) 1 04295875 Gasket, Transmission Pan (42RE trans.) 1 04617196AB Plate, Valve Body Separator (46RE trans.) 1 05012978AA Gasket, Transmission Pan (46RE trans.) 10 05010124AA Fluid, Transmission ATF +3 1(AR) 04669020 Label, Authorized Software Update (if a 46RE trans.) 1(AR) 04275086 Label, Authorized Modification (if a 46RE trans.) Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 21-01-00 > Feb > 00 > A/T Harsh Reverse Gear Engagement > Page 305 REPAIR PROCEDURE: For both the 1999 and 2000 M.Y. 42RE and 46RE Transmission: 1. Refer to the appropriate year information on Transmission and Transfer Case removal and installation instructions of the transmission valve body, check ball, upper housing separator plate, and pan gasket. 2. Replace the original steel rear servo check ball with the plastic "Torlon" check ball (p/n 52118261). 3. Clean the new separator plate to remove any dirt or rust inhibitor prior to installation. 4. Install the new transmission valve body upper housing separator plate (p/n 52118272 or p/n 04617196AB). 5. Reassemble the transmission. 6. Install a new transmission pan gasket (p/n 04295875 or p/n 05012978AA). 7. Lower vehicle and install transmission fluid (p/n 05010124AA). 8. Verify fluid level after warming up the transmission and cycling the shift lever several times. 9. Verify, and if required, adjust the transmission shift linkage and the transmission throttle valve cable per the appropriate Service Manual procedures. For the 2000 M.Y. 46RE Transmission Only: 1. Log onto the MDS2 system. 2. Connect the MDS2 (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and switch the ignition key to "ON". 3. Use the arrow keys and select # 2 CONNECT TO MDS2 on the DRB III MAIN MENU SCREEN. 4. Use the arrow keys and select # 2 RUN MDS2 APPLICATION on the DRB III MAIN MENU SCREEN. NOTE: ONCE MDS2, DRB III, AND VEHICLE COMMUNICATION HAS BEEN ESTABLISHED, THE "CANNOT READ VIN FROM DRB III "MESSAGE (ON THE MDS) WILL BE REPLACED BY THE VEHICLE VIN. PRESS THE "OK" BUTTON ON THE MDS2 TO REQUEST A MDS2 SESSION FOR THE VEHICLE VIN INDICATED. PRESS THE "OK" BUTTON WHEN ASKED TO BEGIN SESSION. 5. Push the FLASH tab on the MDS2. NOTE: A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION. 6. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. NOTE: A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION. 7. Select the new software part number with the light pen and click UPDATE CONTROLLER SOFTWARE. 8. The MDS2 and DRB III will prompt for any operator action needed during the remainder of the reprogramming process. NOTE: DUE TO THE PCM FLASH PROCEDURE, A DTC MAY BE SET IN OTHER MODULES (EATX, BCM, MIC, SKIM, ABS) WITHIN THE VEHICLE IF SO EQUIPPED. SOME MAY CAUSE THE MIL TO ILLUMINATE. ALL DTC'S RELATE TO A LOSS OF COMMUNICATIONS WITH THE MODULE THAT IS BEING FLASHED. CHECK ALL MODULES, RECORD THE FAULTS, AND ERASE THESE FAULTS PRIOR TO RETURNING THE VEHICLE TO THE CUSTOMER. ERASE ANY FAULTS IN THE PCM ONLY AFTER ALL OTHER MODULES HAVE HAD THEIR FAULTS ERASED. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 21-01-00 > Feb > 00 > A/T Harsh Reverse Gear Engagement > Page 306 Fig. 1 9. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Figure 1). Attach the label to the JTEC PCM and cover the label with the clear plastic overlay. Fig. 2 10. Type the necessary information on the "Authorized Modification Label" pin 04275086 and attach the label near the VECI label (Figure 2). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 21-95-01-93 Valve Body, Check Ball and Plate - Replace 1.7 Hrs. 1999-2000 (AB, AN, BR, BE, DN, WJ) 08-19-42-94 Powertrain Control Module - Reprogram (46RE only) 0.5 Hrs. 2000 (AN, AB, BR, BE, DN) FAILURE CODE: P8- New Part FM - Flash Module Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 18-033-04 > Aug > 04 > Engine Controls - Generic Engine Module Programming Powertrain Control Module: All Technical Service Bulletins Engine Controls - Generic Engine Module Programming NUMBER: 18-033-04 GROUP: Vehicle Performance DATE: August 20, 2004 THE DRBIII(R) FLASH FILES FOR THIS BULLETIN ARE AVAILABLE ON DealerCONNECT. FOR MARKETS OUTSIDE OF THE UNITED STATES AND CANADA, THE FLASH FILES AND REPROGRAMMING INSTRUCTIONS WILL BE AVAILABLE ON ITIL/ISIS DVD OCTOBER, 2004. THIS BULLETIN SUPERSEDES SERVICE BULLETIN 18-030-03 REV. A DATED OCTOBER 17, 2003, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES 8 ADDITIONAL PART NUMBERS, AN ADDITIONAL MODEL YEAR, AND AN UPDATED REPAIR PROCEDURE. SUBJECT: Generic Cummins Engine Control Module (ECM) Procedure OVERVIEW: This bulletin involves programming a generic Cummins ECM with software. MODELS NOTE: This bulletin applies to Ram trucks equipped with the 5.9L Cummins 24-valve diesel engine (sales code ETC or ETH). DISCUSSION: Mopar(R) is phasing out pre-programmed Cummins Diesel Engine Control Modules (ECM). New modules will no longer be pre-programmed when received from Mopar(R). Replacement of future ECM's will require programming utilizing the DRBIII(R) and TechCONNECT. 1998 1/2 - 2002 modules will cause the "Wait to Start" light to flash, indicating the module has not been programmed. CAUTION: Extreme care must be taken when programming the flash file of a generic ECM. Do not randomly select a flash file. If in doubt, contact the STAR Center for assistance. Installing an incorrect flash file into an ECM can cause severe engine damage. Once a flash file is selected and programmed, the controller cannot be reprogrammed with a different flash file. The module can only be reprogrammed to a more recent version of the same released flash file. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 18-033-04 > Aug > 04 > Engine Controls - Generic Engine Module Programming > Page 312 PARTS REQUIRED Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 18-033-04 > Aug > 04 > Engine Controls - Generic Engine Module Programming > Page 313 SPECIAL TOOLS/EQUIPMENT REQUIRED: NOTE: An updated J1962 cable has been released. This cable has a red colored connector at the DRBIII(R) connection. Use this cable whenever a flash is being performed. REPAIR PROCEDURE: NOTE: Whenever a controller is programmed, the software in the DRBIII(R) must be programmed with the latest revision level available. NOTE: If this flash process is interrupted/aborted, the flash process should be restarted and then follow the directions on the DRBIII(R). 1. Before beginning the reprogramming procedure, remove any old flash reprogramming files from the DRBIII(R) memory. To clear the memory from the MAIN MENU power up the DRBIII(R) and then: a. Simultaneously press the "MORE" and "YES" keys. b. A screen will appear requesting a "COLD BOOT". c. Follow the on screen instructions by selecting the "F4" key. d. When the DRBIII(R) reboots to the MAIN MENU, proceed to Step # 2. 2. With the ignition switch in the "RUN" position, determine and record the "ECM part number" of the ECM currently in the vehicle. Using the DRBIII(R) select: a. "DRBIII(R) Standalone" b. "1998 - 2005 Diagnostics" c. "All (Except Below)" d. "Engine" e. On 1998 1/2 - 2003 vehicles, select "Cummins". 2004 and later vehicles, proceed to next step. f. "Module Display" g. Record the "ECM part number" on the repair order for later reference. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 18-033-04 > Aug > 04 > Engine Controls - Generic Engine Module Programming > Page 314 NOTE: If the ECM is not operational, the "ECM part number" can be obtained from the label on the controller. For 1998 1/2 - 2002 vehicles, if the label on the controller is not legible, proceed to next step. For 2003 and later vehicles, if the label on the controller is not legible, record the "Reference No." for use later. The "Reference No." is located in the Reference No. box at the top, center of the Engine Data Plate (Fig. 1). Do not use the reference number shown in the figure. The Engine Data Plate is located on the intake side of the breather cover or affixed to the APPS bracket. 3. Page back to the "Main Menu" 4. Determine if the vehicle is equipped with SKIM. Using the DRBIII(R) select: a. "DRBIII Standalone" b. "1998 - 2005 Diagnostics" c. "All" d. "System Monitor" e. "J1850 Module Scan" f. Look for "SKIM" in the list of modules. 5. If the vehicle is not equipped with SKIM then proceed to Step # 6. If the vehicle is equipped with SKIM obtain the vehicle Personal Identification Number (PIN) before continuing with Step # 6. This information is available from: a. The original selling invoice. b. The DealerCONNECT system under the "Sales" or "Parts" tabs - select "Key Codes". c. By contacting the District Manager. CAUTION: Failure to install the SKIM pin number into the module after flashing the Cummins ECM will cause a start and stall condition. 6. Open the hood, install a battery charger and verify that the charging rate provides approximately 13.5 volts. 7. If the old "ECM part number" is known, or for 2003 and later vehicles, proceed to Step # 14. On 1998 1/2 - 2002 vehicles, if the old "ECM part number" is not known, proceed to next step. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 18-033-04 > Aug > 04 > Engine Controls - Generic Engine Module Programming > Page 315 8. On DealerCONNECT select the "Service" tab. 9. Select "Vehicle Information Plus". 10. Select "Single VIN Inquiry". 11. Manually enter the VIN and mileage and select "Enter". 12. Select the "Vehicle Option" tab. 13. Under the "Vehicle Option" window, identify and record: a. Engine (sales code and description). b. Emissions (Federal or California) c. Transmission (Automatic, 5-speed manual, etc.). NOTE: When reprogramming a Cummins ECM be sure to do the following; ^ Download the flash file from TechCONNECT to the DRBIII(R) with the DRBIII(R) disconnected from the vehicle. ^ Download the flash file from the DRBIII(R) to the vehicle with the DRBIII(R) disconnected from TechCONNECT. 14. Connect the DRBIII(R) to TechCONNECT. Open TechTOOLS and verify that the "DRBIII(R) Status: Connected" message is in the upper right corner of the TechTOOLS screen. 15. Enter the old Cummins "ECM part number" obtained from the DRBIII(R) in Step # 2 into the "Parts Criteria" window. 16. Select "Show Updates". 17. Highlight the proper flash file from the list: a. If the old "ECM part number" is known, highlight the flash file listed, based on the old "ECM part number" recorded earlier Step # 2. b. For 1998 1/2 - 2002, if the old "ECM part number" is not known, highlight the correct flash file based on the information that was recorded from "Vehicle Options" Step # 13. c. For 2003 and later, if the old part number is not known, highlight the proper flash file based on the Reference No. located in the "Ref. No." box, at the top, center of the Engine Data Plate (Fig. 1). 18. Select the "DRBIII" radio button which is next to the "Download/Update" button. 19. Select the "Download/Update" button. 20. Monitor the "Flash Download/Update Progress" window on the TechCONNECT and follow the instructions on TechCONNECT. When the flash process is complete, proceed to the next step. 21. Disconnect the DRBIII(R) from TechCONNECT. 22. Connect the DRBIII(R) to the vehicle. 23. Download the flash file from the DRBIII(R) to the vehicle. Using the DRBIII(R) select: a. "Vehicle Flash" b. Follow the directions on the DRBIII(R) screen. When the flash process is complete, proceed to the next step. 24. If the vehicle is equipped with SKIM, proceed to Step # 25. If the vehicle is not equipped with SKIM, proceed to Step # 26. 25. On vehicles equipped with SKIM, transfer the VIN and Security Key information from the SKIM to the ECM. Using the DRBIII(R) select: a. "DRBIII Standalone" Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 18-033-04 > Aug > 04 > Engine Controls - Generic Engine Module Programming > Page 316 b. "1998 - 2005 Diagnostics" c. "All" d. "TheftAlarm" e. "SKIM" f. "Miscellaneous" g. "Cummins ECM Replaced" h. Follow the directions on the DRBIII(R) screen. When the process is complete, proceed to Step # 27. 26. On vehicles not equipped with SKIM, manually enter the VIN in the ECM. Using the DRBIII(R) select: a. "DRBIII Standalone" b. "1998 - 2005 Diagnostics" c. "All" d. "Engine" e. "Cummins Controller (ECM/ENGINE)" f. "Miscellaneous" g. "CM84X Check VIN" h. Follow the directions on the DRBIII(R) screen. When the process is complete, proceed to next step. NOTE: Due to the Cummins controller programming procedure, a DTC may be set in other modules (PCM, TCM, BCM, MIC, SKIM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. Check all modules using "Module Scan", record the DTC's, and erase these DTC's prior to returning the vehicle to the customer. Erase any DTC's in the PCM only after all other modules have had their DTC's erased. NOTE: The following step is required by law. 27. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label (Fig. 2). POLICY: Reimbursable within the provisions of the warranty. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 18-033-04 > Aug > 04 > Engine Controls - Generic Engine Module Programming > Page 317 TIME ALLOWANCE: Refer to Quick Labor Operations or the appropriate Labor Operation Time Schedule manual. Disclaimer This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 318 Powertrain Control Module: Specifications ECM Mounting Bolts 24 Nm PCM Mounting Bolts 4 Nm Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Locations > Component Locations Powertrain Control Module: Component Locations Powertrain Control Module (PCM) PCM Location And Mounting The PCM is bolted to the firewall in the right-rear side of the engine compartment. Engine Control Module (ECM) Engine Control Module (ECM) Location The Engine Control Module (ECM) is bolted to the left side of the engine behind the fuel filter. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Locations > Component Locations > Page 321 Engine Control Module (ECM), Hex Headed Bolt, 50-way Connector, Fuel Transfer Pump, Mounting Bolts (3) Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions Powertrain Control Module: Diagram Information and Instructions Introduction General Information (Part 1 Of 2) Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 324 General Information (Part 2 Of 2) Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Function Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 325 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 326 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 327 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 328 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 329 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 330 Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 331 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 332 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 333 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 334 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 335 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Terminal/Connector Repair-Thomas and Betts Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 336 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector. Removing Wire Terminal 4. Insert the probe end of Special Tool 6934 into the back of the connector cavity. 5. Grasp the wire and Special Tool 6934 and slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal. 7. Install the wire and terminal in the connector. Fully seat the terminal in the connector. Single Lock Tab 8. Push in the single lock tab on the side of the connector. Wiring Repair Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 337 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 338 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 339 Powertrain Control Module: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 340 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 341 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 342 Powertrain Control Module: Connector Views Diesel Engine Control Module - Diesel Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 343 Powertrain Control Module C1 Powertrain Control Module C2 Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 344 Powertrain Control Module C3 Gasoline Engine Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 345 Powertrain Control Module C1 Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 346 Powertrain Control Module C2 Powertrain Control Module C3 Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > System Operation Powertrain Control Module: Description and Operation System Operation The speed control electronic control circuitry is integrated into the Powertrain Control Module (PCM). The PCM is located in the engine compartment. The PCM speed control functions are monitored by the On-Board Diagnostics (OBD). All OBD sensed systems are monitored by the PCM. Each monitored circuit is assigned a Diagnostic Trouble Code (DTC). The PCM will store a DTC in electronic memory for certain failures it detects. See On-Board Diagnostic Test For Speed Control System for more information. The PCM cannot be repaired and must be replaced if faulty. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > System Operation > Page 349 Powertrain Control Module: Description and Operation 46/47RE Transmission The PCM controls operation of the converter clutch, overdrive clutch, and governor pressure solenoid. The control module determines transmission shift points based on input signals from the transmission thermistor, transmission output shaft speed sensor, crankshaft position sensor, vehicle speed sensor, throttle position sensor, and battery temperature sensor. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions Powertrain Control Module: Diagnostic Trouble Code Descriptions Trouble Codes Trouble Code Descriptions For Information regarding diagnosis of all B, C, P, U and Manufacturer Codes See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Service and Repair > Powertrain Control Module (PCM) Powertrain Control Module: Service and Repair Powertrain Control Module (PCM) PCM Location And Mounting The PCM is bolted to the firewall in the right-rear side of the engine compartment. REMOVAL To avoid possible voltage spike damage to the PCM, ignition key must be off, and negative battery cable must be disconnected before unplugging PCM connectors. 1. Disconnect negative battery cable(s) at battery's). 2. Remove cover over electrical connectors. Cover snaps onto PCM. 3. Carefully unplug the three 32-way connectors from PCM. 4. Remove three PCM mounting bolts and remove PCM from vehicle. INSTALLATION 1. Install PCM and mounting bolts to vehicle. 2. Tighten bolts to 4 Nm (35 in. lbs.). 3. Check pin connectors in the PCM and the three 32-way connectors for corrosion or damage. Repair as necessary. 4. Install three 32-way connectors. 5. Install cover over electrical connectors. Cover snaps onto PCM. 6. Install battery cable(s)). 7. Use the DRB scan tool to reprogram new PCM with vehicles original Identification Number (VIN) and original vehicle mileage. If this step is not done, a Diagnostic 'Trouble Code (DTC) may be set. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Service and Repair > Powertrain Control Module (PCM) > Page 354 Powertrain Control Module: Service and Repair Engine Control Module (ECM) - Diesel Engine Control Module (ECM) Location And Mounting The ECM is bolted to the engine block behind the fuel filter. REMOVAL 1. Record any Diagnostic Trouble Codes (DTC's) found in the PCM or ECM. To avoid possible voltage spike damage to either the Powertrain Control Module (PCM) or ECM, ignition key must be off, and negative battery cables must be disconnected before unplugging ECM connectors. 2. Disconnect both negative battery cables at both batteries. 3. Remove 50-way electrical connector bolt at ECM. Note: Connector bolt is female 4mm hex head. To remove bolt, use a ball-hex bit or ball- hex screwdriver such as Snap-On(R) 4 mm SDABM4 (5/32" may also be used). As bolt is being removed, very carefully remove connector from ECM. 4. Remove three ECM mounting bolts and remove ECM from vehicle. INSTALLATION Do not apply paint to back of ECM. Poor ground will result. 1. Clean ECM mounting points at engine block. 2. Position ECM to engine block and install 3 mounting bolts. Tighten bolts to 24 Nm (18 ft. lbs.). 3. Check pin connectors in ECM and 50-way connector for corrosion or damage. Repair as necessary. 4. Clean pins in 50-way electrical connector with a quick-dry electrical contact cleaner. 5. Very carefully install 50-way connector to ECM. tighten connector hex bolt. 6. Install battery cables. 7. Turn key to ON position. Without starting engine, slowly press throttle pedal to floor and then slowly release. This step must be done (one time) to ensure accelerator pedal position sensor calibration has been learned by ECM. If not done, possible DTC's may be set. 8. Use DRB scan tool to erase any stored companion DTC's from PCM. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations Automatic Shut Down (ASD) Relay: Locations Power Distribution Center (PDC) Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 358 8w-10-2 The ASD relay is located in the Power Distribution Center (PDC), in the engine compartment. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 359 Automatic Shut Down (ASD) Relay: Diagrams Power Distribution Center (PDC) Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 360 Automatic Shut Down (ASD) Relay Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations Fuel Pump Relay: Locations Power Distribution Center (PDC) Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 365 8w-10-2 The fuel pump relay is located in the Power Distribution Center (PDC). Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 366 Fuel Pump Relay: Diagrams Power Distribution Center (PDC) Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 367 Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 368 Fuel Pump Relay: Description and Operation FUEL INJECTION PUMP RELAY-ECM OUTPUT The Engine Control Module (ECM) energizes the electric fuel injection pump through the fuel injection pump relay. Battery voltage is applied to the fuel injection pump relay at all times. When the key is turned ON, the relay is energized when a 12-volt signal is provided by the ECM. When energized, 12-volts is supplied to the Fuel Pump Control Module. The Fuel Pump Control Module is located on the top of the fuel injection pump and is non-serviceable. The fuel injection pump relay is located in the Power Distribution Center (PDC). Refer to label under PDC cover for relay location. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Intake Air Heater Relay > Component Information > Locations > Component Locations Intake Air Heater Relay: Component Locations Intake Manifold Air Heater Relays The relays are located in engine compartment, bolted to left inner fender below left battery. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Intake Air Heater Relay > Component Information > Locations > Component Locations > Page 373 Relay Output To Heater, Heater Relay #1, Heater Relay #2 Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Intake Air Heater Relay > Component Information > Diagrams > Intake Air Heater Relay No.1 Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Intake Air Heater Relay > Component Information > Diagrams > Intake Air Heater Relay No.1 > Page 376 Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Intake Air Heater Relay > Component Information > Diagrams > Page 377 Intake Air Heater Relay: Service and Repair Intake Manifold Air Heater Relays The relays are located in engine compartment, bolted to left inner fender below left battery. REMOVAL The mounting bracket and both relays are replaced as an assembly. 1. Disconnect both negative battery cables at both batteries. 2. Disconnect four relay trigger wires at both relays. Note position of wiring before removing. 3. Lift four rubber shields from all 4 cables . 4. Remove four nuts at cable connectors. Note position of wiring before removing. 5. Remove three relay mounting bracket bolts and remove relay assembly. INSTALLATION 1. Install relay assembly to inner fender. tighten mounting bolts to 4.5 Nm (40 in. lbs.) torque. 2. Connect eight electrical connectors to relays. 3. Connect battery cables to both batteries. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations Automatic Shut Down (ASD) Relay: Locations Power Distribution Center (PDC) Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 381 8w-10-2 The ASD relay is located in the Power Distribution Center (PDC), in the engine compartment. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 382 Automatic Shut Down (ASD) Relay: Diagrams Power Distribution Center (PDC) Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 383 Automatic Shut Down (ASD) Relay Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 08-32-99 > Oct > 99 > Two Way Radio Intermittent Poor Reception Air Bag Control Module: Customer Interest Two Way Radio - Intermittent Poor Reception NUMBER: 08-32-99 GROUP: Electrical DATE: Oct. 1, 1999 SUBJECT: Radio Interference To/From Two-Way Radio Receivers OVERVIEW: This bulletin involves installing a revised Airbag Control Module (ACM). MODELS: 1998 - 1999 (BR/BE) Ram Truck SYMPTOM/CONDITION: Customers may complain of intermittent poor reception on their two-way radios. NOTE: THIS CONDITION DOES NOT AFFECT THE OPERATION OF ANY AM OR FM BAND RADIO. DISCUSSION: Radio receivers from approximately 30 MHZ to 50 MHZ may be susceptible to Radio Frequency Interference (RFI) from the Airbag Control Module (ACM). The following services are within this band range of 30 MHZ to 50 MHZ: ^ Public Service Low Band VHF (30 - 50 MHZ) ^ Six Meter Amateur Radio Band (50 - 54 MHZ) DIAGNOSIS: NOTE: TECHNICAL SERVICE BULLETIN 08-06-99, DATED MARCH 5, 1999, ADDRESSES TWO-WAY RADIO INTERFERENCE FROM THE FUEL PUMP MODULE AND SHOULD BE PERFORMED PRIOR TO PERFORMING THIS TECHNICAL SERVICE BULLETIN. Turn the ignition key to the RUN position. Operate the two-way radio and monitor for RFI/static/poor reception. If RFI is present with the ignition key in the RUN position, perform the following Repair Procedure. NOTE: THE INTERFERENCE MAY BE INTERMITTENT. IF THE CONDITION IS NOT PRESENT DURING THE DIAGNOSIS, REPEAT THE DIAGNOSIS SEVERAL TIMES TO ATTEMPT TO RE-CREATE THE CONDITION. NOTE: IT IS IMPORTANT TO IDENTIFY WHICH COMPONENTS ARE EMITTING RFI. AFTER A REPAIR HAS BEEN MADE, PERFORM THE DIAGNOSIS AGAIN TO IDENTIFY IF ANY OTHER COMPONENT IS PRODUCING RFI. SOME VEHICLES MAY REQUIRE ADDITIONAL DIAGNOSIS. PARTS REQUIRED: 1 56043128AE Module, Airbag Control REPAIR PROCEDURE: THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. 1. Replace the ACM with p/n 56043128AE. Refer to the appropriate Ram Truck Service Manual, Group 8M, for information regarding Airbag Control Module Removal And Installation procedures. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 08-32-99 > Oct > 99 > Two Way Radio Intermittent Poor Reception > Page 393 POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-45-09-92 0.3 Hrs. FAILURE CODE: P8 - New Part Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 08-32-99 > Oct > 99 > Two Way Radio - Intermittent Poor Reception Air Bag Control Module: All Technical Service Bulletins Two Way Radio - Intermittent Poor Reception NUMBER: 08-32-99 GROUP: Electrical DATE: Oct. 1, 1999 SUBJECT: Radio Interference To/From Two-Way Radio Receivers OVERVIEW: This bulletin involves installing a revised Airbag Control Module (ACM). MODELS: 1998 - 1999 (BR/BE) Ram Truck SYMPTOM/CONDITION: Customers may complain of intermittent poor reception on their two-way radios. NOTE: THIS CONDITION DOES NOT AFFECT THE OPERATION OF ANY AM OR FM BAND RADIO. DISCUSSION: Radio receivers from approximately 30 MHZ to 50 MHZ may be susceptible to Radio Frequency Interference (RFI) from the Airbag Control Module (ACM). The following services are within this band range of 30 MHZ to 50 MHZ: ^ Public Service Low Band VHF (30 - 50 MHZ) ^ Six Meter Amateur Radio Band (50 - 54 MHZ) DIAGNOSIS: NOTE: TECHNICAL SERVICE BULLETIN 08-06-99, DATED MARCH 5, 1999, ADDRESSES TWO-WAY RADIO INTERFERENCE FROM THE FUEL PUMP MODULE AND SHOULD BE PERFORMED PRIOR TO PERFORMING THIS TECHNICAL SERVICE BULLETIN. Turn the ignition key to the RUN position. Operate the two-way radio and monitor for RFI/static/poor reception. If RFI is present with the ignition key in the RUN position, perform the following Repair Procedure. NOTE: THE INTERFERENCE MAY BE INTERMITTENT. IF THE CONDITION IS NOT PRESENT DURING THE DIAGNOSIS, REPEAT THE DIAGNOSIS SEVERAL TIMES TO ATTEMPT TO RE-CREATE THE CONDITION. NOTE: IT IS IMPORTANT TO IDENTIFY WHICH COMPONENTS ARE EMITTING RFI. AFTER A REPAIR HAS BEEN MADE, PERFORM THE DIAGNOSIS AGAIN TO IDENTIFY IF ANY OTHER COMPONENT IS PRODUCING RFI. SOME VEHICLES MAY REQUIRE ADDITIONAL DIAGNOSIS. PARTS REQUIRED: 1 56043128AE Module, Airbag Control REPAIR PROCEDURE: THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. 1. Replace the ACM with p/n 56043128AE. Refer to the appropriate Ram Truck Service Manual, Group 8M, for information regarding Airbag Control Module Removal And Installation procedures. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 08-32-99 > Oct > 99 > Two Way Radio - Intermittent Poor Reception > Page 399 POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-45-09-92 0.3 Hrs. FAILURE CODE: P8 - New Part Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Bag Control Module: > 09-006-01 > Aug > 01 > Engine - Oil Pan Gasket Leak Oil Pan Gasket: All Technical Service Bulletins Engine - Oil Pan Gasket Leak NUMBER: 09-006-01 GROUP: Engine DATE: August 24, 2001 SUBJECT: Engine Oil Pan Gasket Sealing MODELS: 1998 - 2002 BE/BR Ram Truck NOTE: THIS BULLETIN APPLIES TO RAM TRUCKS EQUIPPED WITH THE 24-VALVE DIESEL ENGINE. DISCUSSION: Repeat oil pan gasket leaks can occur on 24 Valve Diesels it the gasket is applied without the use of Mopar Silicon Rubber Adhesive (RTV) Sealant (PN 04883971). This bulletin provides specific routing of the sealant when replacing the engine oil pan gasket. When replacing an oil pan gasket, apply a 1/8" bead of RTV to the oil pan side of the gasket, around the back of the engine, extending up to the fourth bolt hole from the rear on each side, as per (Fig. 1). POLICY: Information Only Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 410 Air Bag Control Module: Specifications Tighten the four screws that secure the ACM mounting bracket to the floor panel transmission tunnel to 14 Nm (125 in lbs). Tighten the nuts that secure the instrument panel center support bracket to the studs on the lower instrument panel structural support to 14 Nm (125 in lbs). Tighten the screws that secure each side of the instrument panel center support bracket to the ACM mounting bracket to 14 Nm (125 in lbs). Tighten the two screws that secure the trim cover to the ACM mounting bracket on the floor panel transmission tunnel to 2.2 Nm (20 in lbs). Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 411 Air Bag Control Module: Locations Airbag Control Module Airbag Control Module (ACM) Module Locations Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 412 Airbag Control Module Remove/Install Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 413 Air Bag Control Module: Diagrams Airbag Control Module (ACM) Connector Airbag Control Module - 23 Way Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 414 Air Bag Control Module: Service Precautions WARNING: - THE AIR BAG CONTROL MODULE CONTAINS THE IMPACT SENSOR, WHICH ENABLES THE SYSTEM TO DEPLOY THE AIRBAG. BEFORE ATTEMPTING TO DIAGNOSE OR SERVICE ANY AIRBAG SYSTEM OR RELATED STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENTS YOU MUST FIRST DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE. THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE FURTHER SYSTEM SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO DO THIS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. - NEVER STRIKE OR KICK THE AIR BAG CONTROL MODULE, AS IT CAN DAMAGE THE IMPACT SENSOR OR AFFECT ITS CALIBRATION. IF AN AIRBAG CONTROL MODULE IS ACCIDENTALLY DROPPED DURING SERVICE, THE MODULE MUST BE SCRAPPED AND REPLACED WITH A NEW UNIT FAILURE TO OBSERVE THIS WARNING COULD RESULT IN ACCIDENTAL, INCOMPLETE, OR IMPROPER AIRBAG DEPLOYMENT AND POSSIBLE OCCUPANT INJURIES . Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 415 Air Bag Control Module: Description and Operation DESCRIPTION The Airbag Control Module (ACM) is secured with screws to a mounting bracket located under the instrument panel center support bracket on the floor panel transmission tunnel in the passenger compartment of the vehicle. A plastic trim cover on the floor panel transmission tunnel conceals the ACM and the instrument panel center support bracket. The ACM contains an electronic microprocessor, an electronic impact sensor, an electromechanical safing sensor, and an energy storage capacitor. Club cab and quad cab versions of this vehicle are equipped with a structural seat system. The structural seat system uses an electronic seat belt control system, which includes a Seatbelt Control Timer Module (SCTM). The SCTM has a hard wired fault circuit input to the ACM, which the SCTM uses to signal the status of the electronic seat belt control system to the ACM. If the ACM detects a fault input or no input from the SCTM, it sends messages to the instrument cluster over the CCD data bus to turn on the seat belt reminder lamp. Refer to Seat Belt Control Systems for more information on the electronic seat belt control system and the SCTM. The ACM cannot be repaired or adjusted and, if damaged or faulty, it must be replaced. OPERATION The microprocessor in the ACM contains the airbag system logic. The airbag system logic includes On-Board Diagnostics (OBD), and the ability to communicate with the instrument cluster circuitry over the Chrysler Collision Detection (CCD) data bus to control the airbag indicator lamp. The microprocessor continuously monitors all of the airbag system electrical circuits to determine the system readiness. If the ACM detects a monitored system fault, it sends messages to the instrument cluster over the CCD data bus to turn on the airbag indicator lamp. Refer to Instrument Cluster in Instrument Panel Systems for more information on the airbag indicator lamp. One electronic impact sensor is used in this airbag system. The impact sensor is an accelerometer that senses the rate of vehicle deceleration, which provides verification of the direction and severity of an impact. The impact sensor is calibrated for the specific vehicle, and is only serviced as a unit with the ACM. A pre-programmed decision algorithm in the ACM microprocessor determines when the deceleration rate as signaled by the impact sensor indicates an impact that is severe enough to require airbag system protection. When the programmed conditions are met, the ACM sends an electrical signal to deploy the airbags. In addition to the electronic impact sensor, there is an electromechanical sensor within the ACM called a safing sensor. The safing sensor is a normally open series switch located in the airbag deployment circuit of the ACM. This sensor detects impact energy of a lesser magnitude than the electronic impact sensor, and must be closed in order for the airbags to deploy. The ACM also contains an energy-storage capacitor. This capacitor stores enough electrical energy to deploy the airbags for up to one second following a battery disconnect or failure during an impact. The purpose of the capacitor is to provide airbag system protection in a severe secondary impact, if the initial impact has damaged or disconnected the battery, but was not severe enough to deploy the airbags. A unique feature of the ACM used in this model is that it reads and learns the Vehicle Identification Number (VIN) through messages received from the Powertrain Control Module (PCM) over the CCD data bus. This was done so that the ACM could learn whether the vehicle was equipped with a conventional seat system or the structural seat system. It takes approximately 20 engine start cycles before the complete VIN number is learned and stored in the ACM memory. Once the ACM has stored the VIN information in memory, it cannot be installed in any other vehicle without setting a VIN mismatch fault. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 416 Air Bag Control Module: Service and Repair WARNING: - THE AIR BAG CONTROL MODULE CONTAINS THE IMPACT SENSOR, WHICH ENABLES THE SYSTEM TO DEPLOY THE AIRBAG. BEFORE ATTEMPTING TO DIAGNOSE OR SERVICE ANY AIRBAG SYSTEM OR RELATED STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENTS YOU MUST FIRST DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE. THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE FURTHER SYSTEM SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO DO THIS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. - NEVER STRIKE OR KICK THE AIR BAG CONTROL MODULE, AS IT CAN DAMAGE THE IMPACT SENSOR OR AFFECT ITS CALIBRATION. IF AN AIRBAG CONTROL MODULE IS ACCIDENTALLY DROPPED DURING SERVICE, THE MODULE MUST BE SCRAPPED AND REPLACED WITH A NEW UNIT FAILURE TO OBSERVE THIS WARNING COULD RESULT IN ACCIDENTAL, INCOMPLETE, OR IMPROPER AIRBAG DEPLOYMENT AND POSSIBLE OCCUPANT INJURIES. REMOVAL 1. Disconnect and isolate the battery negative cable. If either of the airbags has not been deployed, wait two minutes for the system capacitor to discharge before further service. 2. If the vehicle is equipped with a manual transmission, remove the center console from the floor panel transmission tunnel. Airbag Control Module Trim Cover Remove/Install 3. If the vehicle is equipped with an automatic transmission, remove the two screws that secure the trim cover to the Airbag Control Module (ACM) mounting bracket on the floor panel transmission tunnel and remove the trim cover. Airbag Control Module Remove/Install 4. Loosen the screw that secures each side of the instrument panel center support bracket to the ACM mounting bracket. Do not remove these screws. 5. Remove the two nuts that secure the instrument panel center support bracket to the studs on the lower instrument panel structural support. 6. Disengage the retainer on the instrument panel wire harness to the ACM from the mounting hole in the left side of the instrument panel center support bracket. 7. Pull the top of the instrument panel center support bracket rearward and down from the instrument panel studs. Fold it down over the top of the ACM until it is laying flat on the floor panel transmission tunnel. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 417 8. Disconnect the instrument panel wire harness connector from the ACM. To disconnect the instrument panel wire harness connector from the ACM: a. Slide the red Connector Position Assurance (CPA) lock on the top of the connector toward the side of the vehicle. b. Depress the connector latch tab and pull the connector straight away from the ACM connector receptacle. NOTE: Always remove and replace the airbag control module and its mounting bracket as a unit. Replacement modules include a replacement mounting bracket. Do not transfer the module to another mounting bracket. 9. Remove the four screws that secure the ACM mounting bracket to the floor panel transmission tunnel. 10. Remove the ACM, the mounting bracket and the instrument panel center support bracket from the floor panel transmission tunnel as a unit. INSTALLATION 1. Carefully position the ACM, the mounting bracket and the instrument panel center support bracket onto the floor panel transmission tunnel. When the ACM is correctly positioned the arrow on the ACM label will be pointed forward in the vehicle. 2. Install and tighten the four screws that secure the ACM mounting bracket to the floor panel transmission tunnel. Tighten the screws to 14 Nm (125 in lbs). 3. With the instrument panel center support bracket still folded down flat on the floor panel transmission tunnel, reconnect the instrument panel wire harness connector to the ACM connector receptacle. Be certain that the connector latch and the red CPA lock are fully engaged. 4. Fold the top of the instrument panel center support bracket up and forward over the studs on the lower instrument panel structural support. 5. Install and tighten the nuts that secure the instrument panel center support bracket to the studs on the lower instrument panel structural support. Tighten the nuts to 14 Nm (125 in lbs). 6. Engage the retainer on the instrument panel wire harness with the mounting hole in the left side of the instrument panel center support bracket. 7. Tighten the screws that secure each side of the instrument panel center support bracket to the ACM mounting bracket. Tighten the screws 14 Nm (125 in lbs). 8. If the vehicle is equipped with a manual transmission, install the center console onto the floor panel transmission tunnel. 9. If the vehicle is equipped with an automatic transmission, position the trim cover over the ACM on the floor panel transmission tunnel. 10. If the vehicle is equipped with an automatic transmission, install and tighten the two screws that secure the trim cover to the ACM mounting bracket on the floor panel transmission tunnel. Tighten the screws to 2.2 Nm (20 in lbs). 11. Do not reconnect the battery negative cable at this time. Refer to Airbag System in the Diagnosis and Testing for the proper procedures. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Belt Control Module > Component Information > Specifications Seat Belt Control Module: Specifications Tighten the two screws that secure the SCTM to the mounting bracket to 2.2 Nm (20 in lbs). Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Belt Control Module > Component Information > Specifications > Page 421 Seat Belt Control Module: Locations Seatbelt Timer Control Module Remove/Install The Seatbelt Control Timer Module (SCTM) is secured to a bracket underneath the front edge of the front seat center cushion. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Belt Control Module > Component Information > Diagrams > Diagram Information and Instructions Seat Belt Control Module: Diagram Information and Instructions Introduction General Information (Part 1 Of 2) Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Belt Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 424 General Information (Part 2 Of 2) Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Function Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Belt Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 425 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Belt Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 426 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Belt Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 427 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Belt Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 428 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Belt Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 429 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Belt Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 430 Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Belt Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 431 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Belt Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 432 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Belt Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 433 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Belt Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 434 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Belt Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 435 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Terminal/Connector Repair-Thomas and Betts Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Belt Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 436 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector. Removing Wire Terminal 4. Insert the probe end of Special Tool 6934 into the back of the connector cavity. 5. Grasp the wire and Special Tool 6934 and slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal. 7. Install the wire and terminal in the connector. Fully seat the terminal in the connector. Single Lock Tab 8. Push in the single lock tab on the side of the connector. Wiring Repair Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Belt Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 437 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Belt Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 438 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Belt Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 439 Seat Belt Control Module: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Belt Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 440 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Belt Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 441 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Belt Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 442 Seat Belt Control Module: Connector Views Seatbelt Control Timer Module Seatbelt Control Timer Module - 13 Way Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Belt Control Module > Component Information > Diagrams > Page 443 Seat Belt Control Module: Description and Operation SEAT BELT CONTROL TIMER MODULE DESCRIPTION The Seat Belt Control Timer Module (SCTM) is secured to a bracket underneath the front edge of the front seat center cushion. The SCTM mounting bracket also serves as the support for the slide-out seat cup holder unit. The SCTM controls the supply of battery current to both of the front seat belt retractor latch solenoids. The SCTM contains an electromechanical Gravity (G)-sensor and an electronic timer circuit. The SCTM monitors the ignition switch state and both door jamb switches through hard-wired inputs. In response to those inputs, the SCTM controls hard-wired outputs to both seat belt retractor latch solenoids. The SCTM also sends diagnostic outputs to the Airbag Control Module (ACM) over a hard-wired fault circuit. For diagnosis of the CCD data bus, the ACM or the fault circuit input to the ACM from the SCTM, the use of a DRB scan tool and the proper Diagnostic Procedures are recommended. The SCTM cannot be repaired. If faulty or damaged, it must be replaced. OPERATION The SCTM provides battery current to energize the seat belt retractor latch solenoids whenever the ignition switch is in the ON or ACCESSORY position, unless the G-sensor input indicates a vehicle condition that requires the set belt retractor to be latched. When the seat belt retractor latch solenoids are energized the retractor spools are unlatched, and the seat belt webbing can be extracted from the retractor. When the solenoids are deenergized the retractor spools latch, preventing the seat belt webbing from being extracted further from the retractor. This logic ensures that the seat belts will latch and/or remain latched if battery power is lost during a vehicle collision. The electromechanical G-sensor within the SCTM monitors the rate of vehicle acceleration and de-acceleration in any horizontal direction. The G-sensor also responds to the horizontal attitude of the vehicle, If the G-sensor monitors a gravity force of greater than about 0.7G in any horizontal direction, or the vehicle is tilted in any direction at an angle of greater than about 45 degrees, the SCTM will de-energize (lock) the seat belt retractor latch solenoids. The SCTM electronic timer circuit provides the vehicle occupants with the ability to extract the seat belt webbing from the retractor spool for a time period of about 30 minutes after the ignition switch is turned to the Off position. The electronic timer circuit also monitors the state of the door jamb switches, and unlatches the seat belt retractors after either door jamb switch cycles from open to closed or from closed to open. Each time the SCTM receives and input indicating a change in the state of a monitored switch, the 30 minute unlatch timer starts again. The timer also is used to de-energize the retractor latch solenoids after about 30 minutes, and prevent the battery from being drained while the vehicle is not being driven. The hard wired SCTM output to the ACM is used to indicate whether a fault condition is present in the structural seat belt control system. The ACM monitors the input from the SCTM and sends the proper messages to the instrument cluster on the Chrysler Collision Detection (CCD) data bus to turn the seat belt reminder lamp ON or OFF. If the ACM receives a fault input or does not detect any input from the SCTM, it sets a fault code and sends messages to the instrument cluster to turn the lamp on. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Belt Control Module > Component Information > Diagrams > Page 444 Seat Belt Control Module: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the fasteners that secure the front seat adjusters to the floor panel. Seatbelt Timer Control Module Remove/Install 3. Tilt the structural seat assembly rearward far enough to reach under the forward edge of the front seat center cushion and access the Seatbelt Control Timer Module (SCTM). 4. Remove the two screws that secure the SCTM to the mounting bracket under the forward edge of the front seat center cushion. 5. Lower the SCTM from the mounting bracket far enough to access and disconnect the front seat wire harness connector from the SCTM connector receptacle. 6. Remove the SCTM from under the front seat. INSTALLATION 1. Tilt the structural seat assembly rearward far enough to reach under the forward edge of the front seat center cushion and install the SCTM. 2. Reconnect the front seat wire harness connector to the SCTM connector receptacle. 3. Position the SCTM to the mounting bracket under the forward edge of the front seat center cushion. 4. Install and tighten the two screws that secure the SCTM to the mounting bracket. Tighten the screws to 2.2 Nm (20 in lbs). 5. Install the fasteners that secure the front seat adjusters to the floor panel. 6. Do not connect the battery negative cable at this time. Refer to Seatbelt Control System Test Mode in the Diagnosis and Testing for the proper procedures. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations Starter Relay: Locations 8w-10-2 The starter relay is located in the Power Distribution Center (PDC), in the engine compartment. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 449 Starter Relay: Diagrams Power Distribution Center (PDC) Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 450 Engine Starter Motor Relay Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 451 Starter Relay: Description and Operation DESCRIPTION The starter relay is an electromechanical device that switches battery current to the pull-in coil of the starter solenoid when the ignition switch is turned to the Start position. The starter relay is located in the Power Distribution Center (PDC), in the engine compartment. See the fuse and relay layout label affixed to the inside surface of the PDC cover for starter relay identification and location. The starter relay is a International Standards Organization (ISO) relay. Relays conforming to the ISO specifications have common physical dimensions, current capacities, terminal patterns, and terminal functions. The starter relay cannot be repaired or adjusted and, if faulty or damaged, it must be replaced. OPERATION The ISO relay consists of an electromagnetic coil, a resistor or diode, and three (two fixed and one movable) electrical contacts. The movable (common feed) relay contact is held against one of the fixed contacts (normally closed) by spring pressure. When the electromagnetic coil is energized, it draws the movable contact away from the normally closed fixed contact, and holds it against the other (normally open) fixed contact. When the electromagnetic coil is de-energized, spring pressure returns the movable contact to the normally closed position. The resistor or diode is connected in parallel with the electromagnetic coil in the relay, and helps to dissipate voltage spikes that are produced when the coil is de-energized. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 452 Starter Relay: Testing and Inspection Starter Relay The starter relay is located in the Power Distribution Center (PDC), in the engine compartment. Refer to the fuse and relay layout label affixed to the underside of the PDC cover for starter relay identification and location. 1. Remove the starter relay from the PDC. Refer to Starter Relay in the Replacement for the procedures. 2. A relay in the de-energized position should have continuity between terminals 87A and 30, and no continuity between terminals 87 and 30. If OK, go to Step 3. If not OK, replace the faulty relay 3. Resistance between terminals 85 and 86 (electromagnet) should be 75 ± 5 ohms. If OK, go to Step 4. If not OK, replace the faulty relay 4. Connect a battery to terminals 85 and 86. There should now be continuity between terminals 30 and 87, and no continuity between terminals 87A and 30. If OK, perform the Relay Circuit Test that follows. If not OK, replace the faulty relay Relay Circuit Test 1. The relay common feed terminal cavity (30) is connected to battery voltage and should be hot at all times. If OK, go to Step 2. If not OK, repair the open circuit to the fuse in the PDC as required. 2. The relay normally closed terminal (87A) is connected to terminal 30 in the de-energized position, but is not used for this application. Go to Step 3. 3. The relay normally open terminal (87) is connected to the common feed terminal (30) in the energized position. This terminal supplies battery voltage to the starter solenoid field coils. There should be continuity between the cavity for relay terminal 87 and the starter solenoid terminal at all times. If OK, go to Step 4. If not OK, repair the open circuit to the starter solenoid as required. 4. The coil battery terminal (86) is connected to the electromagnet in the relay It is energized when the ignition switch is held in the Start position. On vehicles with a manual transmission, the clutch pedal must be fully depressed for this test. Check for battery voltage at the cavity for relay terminal 86 with the ignition switch in the Start position, and no voltage when the ignition switch is released to the On position. If OK, go to Step 5. If not OK with an automatic transmission, check for an open or short circuit to the ignition switch and repair, if required. If the circuit to the ignition switch is OK, refer to Ignition Switch and Key Lock Cylinder in the Diagnosis and Testing of Ignition System for testing of the ignition switch. If not OK with a manual transmission, check the circuit between the relay and the clutch pedal position switch for an open or a short. 5. The coil ground terminal (85) is connected to the electromagnet in the relay On vehicles with a manual transmission, it is grounded at all times. On vehicles with an automatic transmission, it is grounded through the park/neutral position switch only when the gearshift selector lever is in the Park or Neutral positions. Check for continuity to ground at the cavity for relay terminal 85. If not OK with a manual transmission, repair the circuit to ground as required. If not OK with an automatic transmission, check for an open or short circuit to the park/neutral position switch and repair, if required. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 453 Starter Relay: Service and Repair Power Distribution Center REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the cover from the Power Distribution Center (PDC). 3. See the fuse and relay layout label affixed to the underside of the PDC cover for starter relay identification and location. 4. Remove the starter relay from the PDC. INSTALLATION 1. See the fuse and relay layout label affixed to the underside of the PDC cover for the proper starter relay location. 2. Position the starter relay in the proper receptacle in the PDC. 3. Align the starter relay terminals with the terminal cavities in the PDC receptacle. 4. Push down firmly on the starter relay until the terminals are fully seated in the terminal cavities in the PDC receptacle. 5. Install the cover onto the PDC. 6. Reconnect the battery negative cable. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set Control Module: Customer Interest TCM - MIL ON/DTC P1763 Set NUMBER: 21-04-00 GROUP: Transmission DATE: June 3O, 2000 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-07-99, DATED APRIL 30, 1999, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE REVISED MODEL YEARS. SUBJECT: Erroneous MIL Illumination For P1763 - Trans. Governor Pressure Sensor Volts Too High OVERVIEW: This bulletin involves selectively erasing and reprogramming the JTEC Powertrain Control Module (PCM) with new software (calibration change 96Cal18, 97Cal18, 98Cal12, and 99Cal14). MODELS: **1996** - 1999 (AB) Ram Van **1996** - 1999 (AN) Dakota **1996** - 1999 (BR/BE) Ram Truck 1998 - 1999 (DN) Durango **1997** - 1999 (TJ) Wrangler **1996** 1999 (XJ) Cherokee **1996** - 1998 (ZJ) Grand Cherokee NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH AN RE SERIES AUTOMATIC TRANSMISSION BUILT BEFORE DECEMBER 18, 1998 (MDH 1218XX). SYMPTOM/CONDITION: Some vehicles may exhibit a MIL illumination with a Diagnostic Trouble Code (DTC) of P1763 - Transmission Governor Pressure Sensor Volts Too High. The vehicle operator may experience slower than normal vehicle accelerations because the transmission may have temporarily entered its third gear "Limp-In" mode as a result of the DTC. The "Limp-In" mode may last until the vehicle owner cycles the ignition key. The technician may not detect a problem with the automatic transmission during a diagnostic test or test drive. The MIL is caused by an increase in hydraulic pressure. The increased hydraulic pressure is the result of a new valve body machining process, which entered into production January 1, 1998. This condition will occur most often with vehicles that were built between January 1, 1998 and December 18, 1998. Vehicles built prior to January 1,1998 may also experience this condition if the valve body or the transmission assembly is replaced with components built after January 1, 1998. DIAGNOSIS: Using the Mopar Diagnostic System (MDS2) and or the Diagnostic Scan Tool (DRB III(R)), with the appropriate Diagnostic Procedures Manual, verify that all engine and transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If no DTC's are present, and the above symptom has been experienced, perform the Repair Procedure. NOTE: WHENEVER A POWERTRAIN (PCM) IS REPLACED DUE TO FAILURE, THE SOFTWARE OF THE REPLACEMENT CONTROLLER MUST BE VERIFIED FOR THE LATEST REVISION LEVEL. USE THE FLASH PROCEDURE TO UPDATE REPLACED CONTROLLERS AS NECESSARY. PARTS REQUIRED: 1 04669020 Label, Authorized Software Update 1 04275086 Label, Authorized Modification EQUIPMENT REQUIRED: 1 CH6000 Scan Tool (DRB III(R)) 1 CH7035 General Purpose Interface Bus Cable (GPIB) Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set > Page 464 1 CH7000/7001 J1962 Cable 1 MDS2 NOTE: THE MDS2 AND DRB III(R) ARE REQUIRED TO PERFORM PART OF THIS REPAIR. WHEN USING THE MDS2 AND THE DRB III(R), THE SYSTEM MUST BE OPERATING AT CIS CD 2061 OR HIGHER. REPAIR PROCEDURE: 1. Log onto the MDS2 system. 2. Connect the MDS2 and DRB III(R) to the vehicle and switch the ignition key to "ON". 3. Use the arrow keys and select # 2 CONNECT TO MDS2 on the DRB III(R) MAIN MENU SCREEN. 4. Use the arrow keys and select # 2 RUN MDS2 APPLICATION on the DRB III(R) MAIN MENU SCREEN. NOTE: ONCE MDS2, DRB III(R), AND VEHICLE COMMUNICATION HAS BEEN ESTABLISHED, THE "CANNOT READ VIN FROM DRB III(R)" MESSAGE (ON THE MDS2) WILL BE REPLACED BY THE VEHICLE VIN. PRESS THE "OK" BUTTON ON THE MDS2 TO REQUEST A MDS2 SESSION FOR THE VEHICLE VIN INDICATED. PRESS THE "OK" BUTTON WHEN ASKED TO BEGIN SESSION. 5. Select the FLASH tab on the MDS2. 6. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. Press the "OK" button. NOTE: IN ABOVE STEPS # 5 AND/OR # 6, A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION. 7. Select the new software part number with the light pen and click UPDATE CONTROLLER SOFTWARE. 8. The MDS2 and DRB III(R) will prompt for any operator action needed during the remainder of the reprogramming process. NOTE: DUE TO THE PCM REPROGRAMMING PROCEDURE, A DTC MAY BE SET IN OTHER MODULES (EATX, BCM, MIC, SKIM) WITHIN THE VEHICLE, IF SO EQUIPPED. SOME DTC'S MAY CAUSE THE MIL TO ILLUMINATE. ALL DTC'S RELATE TO A LOSS OF COMMUNICATIONS WITH THE MODULE THAT IS BEING REPROGRAMMED. CHECK ALL MODULES, RECORD THE FAULTS, AND ERASE THESE FAULTS PRIOR TO RETURNING THE VEHICLE TO THE CUSTOMER. ERASE ANY FAULTS IN THE PCM ONLY AFTER ALL OTHER MODULES HAVE HAD THEIR FAULTS ERASED. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. 9. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Figure 1). Attach the label to the JTEC PCM and cover the label with the clear plastic overlay. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set > Page 465 10. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI label (Figure 2). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-42-99 0.5 Hrs. FAILURE CODE: FM - Flash Module Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set Control Module: All Technical Service Bulletins TCM - MIL ON/DTC P1763 Set NUMBER: 21-04-00 GROUP: Transmission DATE: June 3O, 2000 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-07-99, DATED APRIL 30, 1999, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE REVISED MODEL YEARS. SUBJECT: Erroneous MIL Illumination For P1763 - Trans. Governor Pressure Sensor Volts Too High OVERVIEW: This bulletin involves selectively erasing and reprogramming the JTEC Powertrain Control Module (PCM) with new software (calibration change 96Cal18, 97Cal18, 98Cal12, and 99Cal14). MODELS: **1996** - 1999 (AB) Ram Van **1996** - 1999 (AN) Dakota **1996** - 1999 (BR/BE) Ram Truck 1998 - 1999 (DN) Durango **1997** - 1999 (TJ) Wrangler **1996** 1999 (XJ) Cherokee **1996** - 1998 (ZJ) Grand Cherokee NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH AN RE SERIES AUTOMATIC TRANSMISSION BUILT BEFORE DECEMBER 18, 1998 (MDH 1218XX). SYMPTOM/CONDITION: Some vehicles may exhibit a MIL illumination with a Diagnostic Trouble Code (DTC) of P1763 - Transmission Governor Pressure Sensor Volts Too High. The vehicle operator may experience slower than normal vehicle accelerations because the transmission may have temporarily entered its third gear "Limp-In" mode as a result of the DTC. The "Limp-In" mode may last until the vehicle owner cycles the ignition key. The technician may not detect a problem with the automatic transmission during a diagnostic test or test drive. The MIL is caused by an increase in hydraulic pressure. The increased hydraulic pressure is the result of a new valve body machining process, which entered into production January 1, 1998. This condition will occur most often with vehicles that were built between January 1, 1998 and December 18, 1998. Vehicles built prior to January 1,1998 may also experience this condition if the valve body or the transmission assembly is replaced with components built after January 1, 1998. DIAGNOSIS: Using the Mopar Diagnostic System (MDS2) and or the Diagnostic Scan Tool (DRB III(R)), with the appropriate Diagnostic Procedures Manual, verify that all engine and transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If no DTC's are present, and the above symptom has been experienced, perform the Repair Procedure. NOTE: WHENEVER A POWERTRAIN (PCM) IS REPLACED DUE TO FAILURE, THE SOFTWARE OF THE REPLACEMENT CONTROLLER MUST BE VERIFIED FOR THE LATEST REVISION LEVEL. USE THE FLASH PROCEDURE TO UPDATE REPLACED CONTROLLERS AS NECESSARY. PARTS REQUIRED: 1 04669020 Label, Authorized Software Update 1 04275086 Label, Authorized Modification EQUIPMENT REQUIRED: 1 CH6000 Scan Tool (DRB III(R)) 1 CH7035 General Purpose Interface Bus Cable (GPIB) Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set > Page 471 1 CH7000/7001 J1962 Cable 1 MDS2 NOTE: THE MDS2 AND DRB III(R) ARE REQUIRED TO PERFORM PART OF THIS REPAIR. WHEN USING THE MDS2 AND THE DRB III(R), THE SYSTEM MUST BE OPERATING AT CIS CD 2061 OR HIGHER. REPAIR PROCEDURE: 1. Log onto the MDS2 system. 2. Connect the MDS2 and DRB III(R) to the vehicle and switch the ignition key to "ON". 3. Use the arrow keys and select # 2 CONNECT TO MDS2 on the DRB III(R) MAIN MENU SCREEN. 4. Use the arrow keys and select # 2 RUN MDS2 APPLICATION on the DRB III(R) MAIN MENU SCREEN. NOTE: ONCE MDS2, DRB III(R), AND VEHICLE COMMUNICATION HAS BEEN ESTABLISHED, THE "CANNOT READ VIN FROM DRB III(R)" MESSAGE (ON THE MDS2) WILL BE REPLACED BY THE VEHICLE VIN. PRESS THE "OK" BUTTON ON THE MDS2 TO REQUEST A MDS2 SESSION FOR THE VEHICLE VIN INDICATED. PRESS THE "OK" BUTTON WHEN ASKED TO BEGIN SESSION. 5. Select the FLASH tab on the MDS2. 6. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. Press the "OK" button. NOTE: IN ABOVE STEPS # 5 AND/OR # 6, A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION. 7. Select the new software part number with the light pen and click UPDATE CONTROLLER SOFTWARE. 8. The MDS2 and DRB III(R) will prompt for any operator action needed during the remainder of the reprogramming process. NOTE: DUE TO THE PCM REPROGRAMMING PROCEDURE, A DTC MAY BE SET IN OTHER MODULES (EATX, BCM, MIC, SKIM) WITHIN THE VEHICLE, IF SO EQUIPPED. SOME DTC'S MAY CAUSE THE MIL TO ILLUMINATE. ALL DTC'S RELATE TO A LOSS OF COMMUNICATIONS WITH THE MODULE THAT IS BEING REPROGRAMMED. CHECK ALL MODULES, RECORD THE FAULTS, AND ERASE THESE FAULTS PRIOR TO RETURNING THE VEHICLE TO THE CUSTOMER. ERASE ANY FAULTS IN THE PCM ONLY AFTER ALL OTHER MODULES HAVE HAD THEIR FAULTS ERASED. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. 9. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Figure 1). Attach the label to the JTEC PCM and cover the label with the clear plastic overlay. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set > Page 472 10. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI label (Figure 2). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-42-99 0.5 Hrs. FAILURE CODE: FM - Flash Module Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 473 Control Module: Description and Operation This vehicle does not have a Transmission Control Module. Transmission control is accomplished through the Engine Control Module or Powertrain Control Module. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations 8w-10-2 Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations > Page 477 Transmission Control System Relay: Diagrams Power Distribution Center (PDC) Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations > Page 478 Transmission Control Relay Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions Windshield Washer Control Module: Diagram Information and Instructions Introduction General Information (Part 1 Of 2) Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 484 General Information (Part 2 Of 2) Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Function Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 485 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 486 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 487 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 488 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 489 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 490 Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 491 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 492 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 493 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 494 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 495 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Terminal/Connector Repair-Thomas and Betts Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 496 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector. Removing Wire Terminal 4. Insert the probe end of Special Tool 6934 into the back of the connector cavity. 5. Grasp the wire and Special Tool 6934 and slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal. 7. Install the wire and terminal in the connector. Fully seat the terminal in the connector. Single Lock Tab 8. Push in the single lock tab on the side of the connector. Wiring Repair Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 497 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 498 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 499 Windshield Washer Control Module: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 500 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 501 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Technical Service Bulletins > Wiper Module - CTM Mandatory PROM Update Technical Service Bulletin # 08-43-99 Date: 991217 Wiper Module - CTM Mandatory PROM Update NUMBER: 08-43-99 GROUP: Electrical DATE: Dec. 17, 1999 SUBJECT: Central Timer Module Software Update When A Wiper Module Is Replaced OVERVIEW: This bulletin involves selectively erasing and reprogramming the Central Timer Module (CTM) with new software (EEPROM changes). MODELS: 1998 - 1999 (BR/BE) Ram Trucks NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH REMOTE KEYLESS ENTRY. DISCUSSION: Due to a design change in MOPAR replacement wiper modules, the CTM must be updated with new software in order to allow the wiper module to function properly. This following Repair Procedure must be performed any time the wiper module is replaced. EQUIPMENT REQUIRED: 1 CH6OOO Scan Tool (DRB III) 1 CH7035 General Purpose Interface Bus Cable (GPIB) 1 CH7OOO/7001 J1962 Cable 1 CH7025 DIN Power Cable 1 MDS2 NOTE: THE MDS2 AND DRB III ARE REQUIRED TO PERFORM PART OF THIS REPAIR. THE MDS2 SYSTEM MUST BE OPERATING AT CIS CD2046 OR HIGHER. THE DRB III MUST BE OPERATING AT VERSION LEVEL 30.9 OR HIGHER. POLICY: Reimbursabie within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-22-90 0.2 Hrs. FAILURE CODE: FM - Flash Module CTM Flash With Vehicle Connected to DRBIII and MDS2 1. Log onto the MDS2 system. 2. Connect the MDS2 (Mopar Diagnostic System) to the DRB III (Scan Tool) with the GPIB cable. Connect the DRB III to the vehicle with the J1962 cable and switch the ignition key to "ON". 3. Use the arrow keys and select option # 2, "CONNECT TO MDS1 OR MDS2," on the DRB III MAIN MENU SCREEN. 4. Use the arrow keys and select option # 2, "RUN MDS2 APPLICATION," on the DRB III. NOTE: ONCE MDS2, DRB III, AND VEHICLE COMMUNICATION HAS BEEN ESTABLISHED, THE "CANNOT READ VIN FROM DRB III" MESSAGE (ON THE MDS2) WILL BE REPLACED BY THE VEHICLE VIN. PRESS THE "OK" BUTTON ON THE MDS2 TO REQUEST A MDS2 SESSION FOR THE VEHICLE VIN INDICATED. PRESS THE "OK" BUTTON WHEN ASKED TO BEGIN SESSION. 5. Push the FLASH tab on the MDS2. NOTE: A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVELS AS LISTED EARLIER IN THIS BULLETIN. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Technical Service Bulletins > Wiper Module - CTM Mandatory PROM Update > Page 506 6. Select "READ PART NUMBERS FROM VEHICLE" and click "SHOW UPDATES" on the MDS2. NOTE: A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVELS AS LISTED EARLIER IN THIS BULLETIN. 7. Select the new CTM software part number with the light pen and click UPDATE CONTROLLER SOFTWARE. 8. The MDS2 and DRB III will download software files to the DRB Ill® and program CTM in approximately 30 seconds. 9. When MDS2 status box reads "Check DRB Screen For Important Instructions," proceed with the instructions identified on the DRB III screen. CTM Flash With DRBIII In Disconnected Mode 1. Log onto the MDS2 system. 2. A MDS2 session can be started by either entering the VIN or by selecting the appropriate Year, Model, and Engine. CAUTION: MDS2 SYSTEM SOFTWARE OPERATING AT CIS CD2046 WILL NOT DISPLAY ANY AVAILABLE CTM FLASHES WHEN A SESSION IS STARTED BY SELECTING YEAR, MODEL, AND ENGINE FOR 1998 5.9L CUMMINS 16 (12 VALVE ENGINE). SELECT THE 1998 5.9L 24 VALVE CUMMINS ENGINE IF IT BECOMES NECESSARY TO FLASH A CTM ON A 1998 5.9L CUMMINS 16 (12 VALVE ENGINE). ALL SUBSEQUENT (CIS CD2047 OR HIGHER) MDS2 RELEASES WILL FUNCTION PROPERLY. 3. Connect the DRB III to the MDS2 (Mopar Diagnostic System) with the GPIB cable and the DIN cable. 4. Use the arrow keys and select option # 2, "CONNECT TO MDS1 OR MDS2," on the DRB III MAIN MENU SCREEN 5. Use the arrow keys and select option # 2, "RUN MDS2 APPLICATION," on the DRB III. 6. Once the vehicle information has been entered, push the FLASH tab on the MDS2. NOTE: A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVELS AS LISTED EARLIER IN THIS BULLETIN. 7. Using the light pen, scroll to the bottom of the list of available flashes and select all available CTM software part numbers, then click DOWNLOAD SOFTWARE TO DRB III. It will take less than one minute to download the software into the DRB III. NOTE: PART NUMBERS LISTED ARE SOFTWARE PART NUMBERS ONLY AND MAY NOT MATCH THE ACTUAL CTM PART NUMBER IDENTIFIED ON THE CTM. IN ADDITION, THE SOFTWARE PART NUMBER WILL NOT MATCH THE SOFTWARE VERSION NUMBER THAT WILL BE IDENTIFIED WHEN USING DRB III "STAND ALONE" MODE TO COMMUNICATE TO THE CTM. 8. Once the software has been downloaded, a dialog box will appear identifying that the download was successful. Select OK. 9. Disconnect the DRB III from the MDS2 and connect the DRB III to the vehicle. 10. Connect the DRB III to the vehicle and switch the ignition key to the RUN position. 11. Use the arrow keys and select option # 2, "CONNECT TO MDS1 OR MDS2," on the DRB III MAIN MENU SCREEN. 12. Use the arrow keys and select option # 2, "RUN MDS2 APPLICATION," on the DRB III. 13. Wait for the "MDS2 diagnostic mode" menu to appear on the DRB III. 14. Use the arrow keys and select option # 2, "PROGRAM VEHICLE CONTROLLERS," from the DRB III menu screen. 15. If the vehicle is equipped with a CTM, the CTM software part number will be displayed on the DRB III. Select the CTM flash software part number. 16. Use the Page FWD key on the DRB III to download the software into the CTM. A status screen will display "UPDATE IN PROGRESS" as the software is downloaded into the CTM. 17. To have the DRB III properly verify the CTM software part number, turn the ignition key to OFF when prompted by DRB III. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Technical Service Bulletins > Wiper Module - CTM Mandatory PROM Update > Page 507 18. Turn the ignition key to back to RUN when the prompted by DRB III. The DRB III will then confirm that the download was successful by displaying the message CTM REPROGRAMMING WAS SUCCESSFUL. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Locations > Central Timer Module (Base) Central Time Module (Base) Remove/Install Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Locations > Central Timer Module (Base) > Page 510 Central Time Module (High-Line) Remove/Install Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions Wiper Control Module: Diagram Information and Instructions Introduction General Information (Part 1 Of 2) Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 513 General Information (Part 2 Of 2) Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Function Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 514 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 515 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 516 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 517 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 518 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 519 Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 520 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 521 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 522 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 523 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 524 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Terminal/Connector Repair-Thomas and Betts Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 525 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector. Removing Wire Terminal 4. Insert the probe end of Special Tool 6934 into the back of the connector cavity. 5. Grasp the wire and Special Tool 6934 and slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal. 7. Install the wire and terminal in the connector. Fully seat the terminal in the connector. Single Lock Tab 8. Push in the single lock tab on the side of the connector. Wiring Repair Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 526 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 527 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 528 Wiper Control Module: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 529 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 530 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations Wiper Relay: Locations 8w-10-2 Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Page 534 Power Distribution Center The intermittent wipe relay is located in the Power Distribution Center (PDC) in the engine compartment. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Diagram Information and Instructions Wiper Relay: Diagram Information and Instructions Introduction General Information (Part 1 Of 2) Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 537 General Information (Part 2 Of 2) Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Function Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 538 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 539 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 540 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 541 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 542 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 543 Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 544 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 545 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 546 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 547 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 548 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Terminal/Connector Repair-Thomas and Betts Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 549 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector. Removing Wire Terminal 4. Insert the probe end of Special Tool 6934 into the back of the connector cavity. 5. Grasp the wire and Special Tool 6934 and slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal. 7. Install the wire and terminal in the connector. Fully seat the terminal in the connector. Single Lock Tab 8. Push in the single lock tab on the side of the connector. Wiring Repair Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 550 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 551 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 552 Wiper Relay: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 553 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 554 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 555 Wiper Relay: Connector Views Power Distribution Center (PDC) Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 556 Wiper Motor Relay Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Page 557 Wiper Relay: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO RESTRAINT SYSTEMS / AIRBAG SYSTEMS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY . Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Page 558 Wiper Relay: Description and Operation SYSTEM OPERATION The intermittent wipe relay is a International Standards Organization (ISO) micro-relay. The terminal designations and functions are the same as a conventional ISO relay. However, the micro-relay terminal orientation (or footprint) is different, current capacity is lower, and the relay case dimensions are smaller than those of the conventional ISO relay. The intermittent wipe relay is a electromechanical device that switches battery current to the windshield wiper motor or wiper motor park switch when the relay coil is grounded by the Central Timer Module (CTM) in response to inputs from the windshield wiper (multi-function) switch. See Intermittent Wipe Relay in the Diagnosis and Testing for more information. The intermittent wipe relay is located in the Power Distribution Center (PDC), in the engine compartment. Refer to the PDC label for relay identification and location. The intermittent wipe relay cannot be repaired and, if faulty or damaged, it must be replaced. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Page 559 Wiper Relay: Testing and Inspection Intermittent Wipe Relay For additional testing and inspection information please refer to Powertrain Management/Computers and Control Systems/ See: Relays and Modules - Powertrain Management/Relays and Modules - Computers and Control Systems/Central Timer Module WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIR BAGS AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Relay Test The intermittent wipe relay is located in the Power Distribution Center (PDC) in the engine compartment. Refer to the PDC label for intermittent wipe relay identification and location. Remove the intermittent wipe relay from the PDC as described in the Replacement to perform the following tests: 1. A relay in the de-energized position should have continuity between terminals 87A and 30, and no continuity between terminals 87 and 30. If OK, go to Step 2.If not OK, replace the faulty relay. 2. Resistance between terminals 85 and 86 (electromagnet) should be 75 ± 5 ohms. If OK, go to Step 3. If not OK, replace the faulty relay. 3. Connect a battery to terminals 85 and 86. There should now be continuity between terminals 30 and 87, and no continuity between terminals 87A and 30. If OK, see Relay Circuit Test in the Diagnosis and Testing. If not OK, a replace the faulty relay. Relay Circuit Test 1. The relay common feed terminal cavity (30) is connected to the wiper (multi-function) switch. There should be continuity between the cavity for relay terminal 30 and the two fused ignition switch output circuit cavities of the multi-function switch wire harness connector at all times. If OK, go to Step 2. If not OK, repair the open circuit(s) to the multifunction switch as required. 2. The relay normally closed terminal (87A) is connected to terminal 30 in the de-energized position. There should be continuity between the cavity for relay terminal 87A and the wiper park switch sense circuit cavities of the wiper motor wire harness connector and the 14-way Central Timer Module (CTM) wire harness connector at all times. If OK, go to Step 3. If not OK, repair the open circuit(s) to the wiper motor and CTM as required. 3. The relay normally open terminal (87) is connected to the common feed terminal (30) in the energized position. There should be battery voltage at the cavity for relay terminal 87 with the ignition switch in the On or Accessory positions. If OK, go to Step 4. If not OK, repair the open circuit to the ignition switch as required. 4. The coil battery terminal (86) is connected to the electromagnet in the relay. There should be battery voltage at the cavity for relay terminal 86 with the ignition switch in the On or Accessory positions. If OK, go to Step 5. If not OK, repair the open circuit to the ignition switch as required. 5. The coil ground terminal (85) is connected to the electromagnet in the relay. It is grounded by the CTM to energize the relay and cycle the wiper motor. Check for continuity between the cavity for relay terminal 85 and the intermittent wiper relay control circuit cavity of the 14-way CTM wire harness connector There should be continuity. If OK, replace the faulty base version CTM; or, use a DRB scan tool and the proper Diagnostic Procedures for diagnosis of the high-line version CTM. If not OK, repair the open circuit to the CTM as required. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Page 560 Wiper Relay: Service and Repair Power Distribution Center REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the cover from the Power Distribution Center (PDC). 3. Refer to the label on the PDC cover for intermittent wipe relay identification and location. 4. Unplug the intermittent wipe relay from the PDC. 5. Install the intermittent wipe relay by aligning the relay terminals with the cavities in the PDC and pushing the relay firmly into place. 6. Install the PDC cover. 7. Connect the battery negative cable. 8. Test the relay operation. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Arm/Disarm Switch, Antitheft > Component Information > Diagrams > Diagram Information and Instructions Arm/Disarm Switch: Diagram Information and Instructions Introduction General Information (Part 1 Of 2) Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Arm/Disarm Switch, Antitheft > Component Information > Diagrams > Diagram Information and Instructions > Page 567 General Information (Part 2 Of 2) Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Function Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Arm/Disarm Switch, Antitheft > Component Information > Diagrams > Diagram Information and Instructions > Page 568 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Arm/Disarm Switch, Antitheft > Component Information > Diagrams > Diagram Information and Instructions > Page 569 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Arm/Disarm Switch, Antitheft > Component Information > Diagrams > Diagram Information and Instructions > Page 570 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Arm/Disarm Switch, Antitheft > Component Information > Diagrams > Diagram Information and Instructions > Page 571 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Arm/Disarm Switch, Antitheft > Component Information > Diagrams > Diagram Information and Instructions > Page 572 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Arm/Disarm Switch, Antitheft > Component Information > Diagrams > Diagram Information and Instructions > Page 573 Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Arm/Disarm Switch, Antitheft > Component Information > Diagrams > Diagram Information and Instructions > Page 574 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Arm/Disarm Switch, Antitheft > Component Information > Diagrams > Diagram Information and Instructions > Page 575 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Arm/Disarm Switch, Antitheft > Component Information > Diagrams > Diagram Information and Instructions > Page 576 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Arm/Disarm Switch, Antitheft > Component Information > Diagrams > Diagram Information and Instructions > Page 577 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Arm/Disarm Switch, Antitheft > Component Information > Diagrams > Diagram Information and Instructions > Page 578 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Terminal/Connector Repair-Thomas and Betts Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Arm/Disarm Switch, Antitheft > Component Information > Diagrams > Diagram Information and Instructions > Page 579 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector. Removing Wire Terminal 4. Insert the probe end of Special Tool 6934 into the back of the connector cavity. 5. Grasp the wire and Special Tool 6934 and slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal. 7. Install the wire and terminal in the connector. Fully seat the terminal in the connector. Single Lock Tab 8. Push in the single lock tab on the side of the connector. Wiring Repair Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Arm/Disarm Switch, Antitheft > Component Information > Diagrams > Diagram Information and Instructions > Page 580 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Arm/Disarm Switch, Antitheft > Component Information > Diagrams > Diagram Information and Instructions > Page 581 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Arm/Disarm Switch, Antitheft > Component Information > Diagrams > Diagram Information and Instructions > Page 582 Arm/Disarm Switch: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Arm/Disarm Switch, Antitheft > Component Information > Diagrams > Diagram Information and Instructions > Page 583 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Arm/Disarm Switch, Antitheft > Component Information > Diagrams > Diagram Information and Instructions > Page 584 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Arm/Disarm Switch, Antitheft > Component Information > Diagrams > Diagram Information and Instructions > Page 585 Arm/Disarm Switch: Connector Views Driver Door Arm/Disarm Switch - Black 2 Way Passenger Door Arm/Disarm Switch - Black 2 Way Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Door Sensor/Switch (For Alarm) > Component Information > Locations Door Sensor/Switch (For Alarm): Locations Door Jamb Switch Remove/Install The door jamb switches are mounted to the door hinge pillars. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Door Sensor/Switch (For Alarm) > Component Information > Diagrams > Diagram Information and Instructions Door Sensor/Switch (For Alarm): Diagram Information and Instructions Introduction General Information (Part 1 Of 2) Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Door Sensor/Switch (For Alarm) > Component Information > Diagrams > Diagram Information and Instructions > Page 591 General Information (Part 2 Of 2) Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Function Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Door Sensor/Switch (For Alarm) > Component Information > Diagrams > Diagram Information and Instructions > Page 592 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Door Sensor/Switch (For Alarm) > Component Information > Diagrams > Diagram Information and Instructions > Page 593 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Door Sensor/Switch (For Alarm) > Component Information > Diagrams > Diagram Information and Instructions > Page 594 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Door Sensor/Switch (For Alarm) > Component Information > Diagrams > Diagram Information and Instructions > Page 595 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Door Sensor/Switch (For Alarm) > Component Information > Diagrams > Diagram Information and Instructions > Page 596 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Door Sensor/Switch (For Alarm) > Component Information > Diagrams > Diagram Information and Instructions > Page 597 Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Door Sensor/Switch (For Alarm) > Component Information > Diagrams > Diagram Information and Instructions > Page 598 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Door Sensor/Switch (For Alarm) > Component Information > Diagrams > Diagram Information and Instructions > Page 599 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Door Sensor/Switch (For Alarm) > Component Information > Diagrams > Diagram Information and Instructions > Page 600 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Door Sensor/Switch (For Alarm) > Component Information > Diagrams > Diagram Information and Instructions > Page 601 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Door Sensor/Switch (For Alarm) > Component Information > Diagrams > Diagram Information and Instructions > Page 602 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Terminal/Connector Repair-Thomas and Betts Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Door Sensor/Switch (For Alarm) > Component Information > Diagrams > Diagram Information and Instructions > Page 603 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector. Removing Wire Terminal 4. Insert the probe end of Special Tool 6934 into the back of the connector cavity. 5. Grasp the wire and Special Tool 6934 and slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal. 7. Install the wire and terminal in the connector. Fully seat the terminal in the connector. Single Lock Tab 8. Push in the single lock tab on the side of the connector. Wiring Repair Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Door Sensor/Switch (For Alarm) > Component Information > Diagrams > Diagram Information and Instructions > Page 604 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Door Sensor/Switch (For Alarm) > Component Information > Diagrams > Diagram Information and Instructions > Page 605 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Door Sensor/Switch (For Alarm) > Component Information > Diagrams > Diagram Information and Instructions > Page 606 Door Sensor/Switch (For Alarm): Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Door Sensor/Switch (For Alarm) > Component Information > Diagrams > Diagram Information and Instructions > Page 607 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Door Sensor/Switch (For Alarm) > Component Information > Diagrams > Diagram Information and Instructions > Page 608 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Door Sensor/Switch (For Alarm) > Component Information > Diagrams > Page 609 Door Sensor/Switch (For Alarm): Description and Operation SYSTEM OPERATION The door jamb switches are mounted to the door hinge pillars. The switches close a path to ground for the Central Timer Module (CTM) when a door is opened, and open the ground path when a door is closed. The door jamb switches cannot be repaired and, if faulty or damaged, they must be replaced. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Door Sensor/Switch (For Alarm) > Component Information > Diagrams > Page 610 Door Sensor/Switch (For Alarm): Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Grasp the body of the door jamb switch with a pair of pliers and move the switch gently back-and-forth while pulling it out of the door hinge pillar mounting hole. Door Jamb Switch Remove/Install 3. Pull the door jamb switch out from the pillar far enough to access the wire harness connector. 4. Unplug the door jamb switch from the wire harness connector. 5. Reverse the removal procedures to install. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Locations Lock Cylinder Switch: Locations Door Lock Cylinder Switch Remove/Install - Typical The door lock cylinder switches are mounted to the back of the key lock cylinder inside each door. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Locations > Page 614 Lock Cylinder Switch: Description and Operation SYSTEM OPERATION The door lock cylinder switches are mounted to the back of the key lock cylinder inside each door. They are normally-open momentary switches that close to ground only when the lock cylinder is rotated to the unlock position. The door lock cylinder switches cannot be repaired and, if faulty or damaged, they must be replaced. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Locations > Page 615 Lock Cylinder Switch: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the door outside latch handle mounting hardware and linkage from the inside of the door. Door Lock Cylinder Switch Remove/Install - Typical 3. From the outside of the door, pull the door outside latch handle out far enough to access the door lock cylinder switch. 4. Disengage the door lock cylinder switch from the back of the lock cylinder. 5. Unplug the door lock cylinder switch wire harness connector. 6. Disengage the retainers that secure the door lock cylinder switch wire harness to the inner door panel. 7. Remove the door lock cylinder switch from the door. 8. Reverse the removal procedures to install. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Locations Remote Radio Switches Remove/Install Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Locations > Page 619 Remote Switch: Diagrams Left Remote Radio Switch Right Remote Radio Switch - 2 Way Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Locations > Page 620 Remote Switch: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIR BAGS AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY . Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Locations > Page 621 Remote Switch: Description and Operation DESCRIPTION A remote radio switch option is available on models equipped with the AM/FM/CD/cassette/3-band graphic equalizer (RAZ sales code) radio receiver and the high-line Central Timer Module (CTM). Refer to Central Timer Module in the Description and Operation of Instrument Panel Systems for more information on this component. Remote Radio Switches Two rocker-type switches are mounted in the sides of the rear (instrument panel side) steering wheel trim cover. The switch on the left side is the seek switch and has seek up, seek down, and preset station advance functions. The switch on the right side is the volume control switch and has volume up, and volume down functions. The two switches are retained in mounting holes located on each side of the rear steering wheel trim cover by four latches that are integral to the switches. The remote radio switches share a common steering wheel wire harness with the vehicle speed control switches. The steering wheel wire harness is connected to the instrument panel wire harness through the clockspring. Refer to Clockspring in the Description and Operation of Passive Restraint Systems for more information on this component. OPERATION The remote radio switches are resistor multiplexed units that are hard wired to the high-line CTM through the clockspring. The CTM monitors the status of the remote radio switches and sends the proper switch status messages on the Chrysler Collision Detection (CCD) data bus network to the radio receiver. The electronic circuitry within the radio is programmed to respond to these remote radio switch status messages by adjusting the radio settings as requested. For diagnosis of the CTM or the CCD data bus, the use of a DRB scan tool and the proper Diagnostic Procedures are recommended. For more information on the features and control functions for each of the remote radio switches, see the owner's manual in the vehicle glove box. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Locations > Page 622 Remote Switch: Testing and Inspection WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIR BAGS AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Remote Radio Switches 1. Remove the remote radio switch(es) from the steering wheel. Remote Radio Switch Test Table 2. Use an ohmmeter to check the switch resistances as shown in the Remote Radio Switch Test chart. If the remote radio switch resistances check OK, go to Step 3. If not OK, replace the faulty switch. 3. Check for continuity between the ground circuit cavity of the remote radio switch wire harness connector and a good ground. There should be continuity If OK, go to Step 4. If not OK, repair the open ground circuit to ground as required. 4. Disconnect the 18-way wire harness connector from the Central Timer Module (CTM). Check for continuity between the radio control mux circuit cavity of the remote radio switch wire harness connector and a good ground. There should be no continuity If OK, go to Step 5. If not OK, repair the shorted radio control mux circuit as required. 5. Check for continuity between the radio control mux circuit cavities of the remote radio switch wire harness connector and the 18-way CTM wire harness connector. There should be continuity. If OK, refer to the proper Diagnostic Procedures to test the CTM and the Chrysler Collision Detection (CCD) data bus. If not OK, repair the open radio control mux circuit as required. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Locations > Page 623 Remote Switch: Service and Repair WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIR BAGS AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the driver side airbag module from the steering wheel. Refer to Driver Side Airbag Module in the Replacement of Passive Restraint Systems for the procedures. 3. Remove the speed control switch located on the same side of the steering wheel as the remote radio switch that is being serviced. Refer to Speed Control Switches in the Replacement of Speed Control System for the procedures. Remote Radio Switches Remove/Install 4. Disconnect the steering wheel wire harness connector from the connector receptacle of the remote radio switch. 5. Disengage the four remote radio switch latches that secure the switch to the inside of the mounting hole in the steering wheel rear trim cover. 6. From the outside of the steering wheel rear trim cover, remove the remote radio switch from the trim cover mounting hole. INSTALLATION 1. Position the remote radio switch to the mounting hole on the outside of the steering wheel rear trim cover. Be certain that the connector receptacle is oriented toward the bottom of the switch and pointed toward the center of the steering wheel. 2. Press firmly and evenly on the remote radio switch until each of the switch latches is fully engaged in the mounting hole of the steering wheel rear trim cover. 3. Reconnect the steering wheel wire harness connector to the connector receptacle of the remote radio switch. 4. Install the speed control switch onto the steering wheel. Refer to Speed Control Switches in the Replacement of Speed Control System for the procedures. 5. Install the driver side airbag module onto the steering wheel. Refer to Driver Side Airbag Module in the Replacement of Passive Restraint Systems for the procedures. 6. Reconnect the battery negative cable. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Diagram Information and Instructions Power Door Lock Switch: Diagram Information and Instructions Introduction General Information (Part 1 Of 2) Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 629 General Information (Part 2 Of 2) Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Function Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 630 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 631 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 632 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 633 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 634 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 635 Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 636 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 637 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 638 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 639 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 640 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Terminal/Connector Repair-Thomas and Betts Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 641 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector. Removing Wire Terminal 4. Insert the probe end of Special Tool 6934 into the back of the connector cavity. 5. Grasp the wire and Special Tool 6934 and slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal. 7. Install the wire and terminal in the connector. Fully seat the terminal in the connector. Single Lock Tab 8. Push in the single lock tab on the side of the connector. Wiring Repair Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 642 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 643 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 644 Power Door Lock Switch: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 645 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 646 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 647 Power Door Lock Switch: Connector Views Driver Door Window/Lock Switch - 16 Way Passenger Door Window/Lock Switch Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Page 648 Power Door Lock Switch: Description and Operation SYSTEM OPERATION The power locks can be controlled by a two-way switch integral to the power window and lock switch and bezel unit on the trim panel of each front door. A Light-Emitting Diode (LED) in the paddle of each switch is illuminated whenever the ignition switch is in the On position. On models with a base version of the Central Timer Module (CTM), the power lock switches are hard-wired to the power lock motors. On models with a high-line version of the CTM, the power lock switch controls the battery feeds to the lock and unlock sense inputs of the high-line CTM. The CTM then relays the correct battery and ground feeds to the power lock motors. The power window and lock switch and bezel unit cannot be repaired and, if faulty or damaged, the entire switch and bezel unit must be replaced. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Page 649 Power Door Lock Switch: Testing and Inspection For additional testing and inspection information please refer to Powertrain Management/Computers and Control Systems/ See: Body and Frame/Body Control Systems/Central Timer Module The Light-Emitting Diode (LED) illumination lamps for all of the power window and lock switch and bezel unit switch paddles receive battery current through the power window circuit breaker in the junction block. If all of the LEDs are inoperative in either or both power window and lock switch and bezel units, refer to Power Window Systems for diagnosis. If only one LED in a power window and lock switch and bezel unit is inoperative, replace the faulty switch and bezel unit. 1. Check the fuse in the junction block. If OK, go to Step 2. If not OK, repair the shorted circuit or component as required and replace the faulty fuse. 2. Check for battery voltage at the fuse in the junction block. If OK, go to Step 3. If not OK, repair the open circuit to the Power Distribution Center (PDC) as required. 3. Disconnect and isolate the battery negative cable. Remove the power window and lock switch and bezel unit from the door trim panel. Unplug the wire harness connector from the switch and bezel unit. 4. Connect the battery negative cable. Check for battery voltage at the fused B(+) circuit cavity of the body half of the power window and lock switch and bezel unit wire harness connector. If OK, go to Step 5. If not OK, repair the open circuit to the junction block as required. Power Lock Switch Continuity - Driver Side Power Lock Switch Continuity - Passenger Side 5. Test the power lock switch continuity See the Power Lock Switch Continuity charts to determine if the continuity is correct in the Neutral, Lock and Unlock switch positions. If OK, repair the door lock switch output (lock and/or unlock) circuit(s) from the body half of the power window and Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Page 650 lock switch and bezel unit wire harness connector to the power lock motors or the high-line version of the Central Timer Module (CTM) as required. If not OK, replace the faulty switch. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Page 651 Power Door Lock Switch: Service and Repair REMOVAL AND INSTALLATION 1. Disconnect and isolate the battery negative cable. Power Window And Lock Switch And Bezel Unit Remove/Install 2. Using a wide flat-bladed tool such as a trim stick, gently pry the upper edge of the switch bezel to release the retainer that secures the switch bezel to the door trim panel opening. 3. Pull the switch and bezel unit away from the door trim panel opening far enough to access and unplug the wire harness connector. 4. Remove the power window and lock switch and bezel unit from the door trim panel. 5. Reverse the removal procedures to install. When installing the switch and bezel unit to the door trim panel opening, insert the rear of the bezel into the opening, then push down on the front of the bezel until the retaining tab snaps into place. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations Power Mirror Switch: Locations Power Mirror Switch Remove/Install - Typical Both the right and left power outside mirrors are controlled by a single multi-function switch unit located on and mounted to the upper flag area of the driver side door trim panel. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations > Page 655 Power Mirror Switch: Description and Operation SYSTEM OPERATION Both the right and left power outside mirrors are controlled by a single multi-function switch unit located on and mounted to the upper flag area of the driver side door trim panel. The switch knob is rotated clockwise (right mirror control), or counterclockwise (left mirror control) to select the mirror to be adjusted. The switch knob is then moved in a joystick fashion to control movement of the selected mirror up, down, right, or left. The power mirror switch cannot be repaired and, if faulty or damaged, it must be replaced. The power mirror switch knob is available for service replacement. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations > Page 656 Power Mirror Switch: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. Power Mirror Switch Remove/Install - Typical 2. Pull the control knob rearward to remove it from the power mirror switch stem. 3. Remove the nut that secures the power mirror switch to the driver side front door trim panel. 4. Remove the trim panel from the inside of the driver side front door. 5. Pull the trim panel away from the inner door far enough to access the power mirror switch wire harness connector. 6. Unplug the power mirror switch wire harness connector. 7. Remove the power mirror switch from the back of the door trim panel. 8. Reverse the removal procedures to install. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Specifications Power Seat Switch: Specifications Tighten the switch mounting screws to 2.2 Nm (20 in lbs). Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Specifications > Page 660 Power Seat Switch: Locations Power Seat Switch Remove/Install - Typical The Power Seat switch is located on the lower outboard side of the driver side seat cushion on the seat cushion side shield on all models. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Specifications > Page 661 Power Seat Switch: Description and Operation SYSTEM OPERATION The power seat in standard cab models can be adjusted in six different ways using the power seat switch. The power seat switch for extended cab models (club cab and quad cab) has an additional switch knob for adjusting the power lumbar support. The switch is located on the lower outboard side of the driver side seat cushion on the seat cushion side shield on all models. Refer to the owner's manual in the vehicle glove box for more information on the power seat switch functions and the seat adjusting procedures. The individual switches in the power seat switch module cannot be repaired. If one switch is damaged or faulty, the entire power seat switch module must be replaced. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Specifications > Page 662 Power Seat Switch: Testing and Inspection 1. Disconnect and isolate the battery negative cable. 2. Remove the power seat switch from the power seat. Power Seat Switch Continuity 3. Use an ohmmeter to test the continuity of the power seat switches in each position. See the Power Seat Switch Continuity chart. If OK, see Power Seat Adjuster and Motors or Power Lumbar Adjuster and Motor in the Diagnosis and Testing. If not OK, replace the faulty power seat switch module. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Specifications > Page 663 Power Seat Switch: Service and Repair REMOVAL Standard Cab 1. Disconnect and isolate the battery negative cable. Seat Switch and Bezel Remove/Install 2. Remove the two screws that secure the power seat switch and bezel unit to the seat cushion frame. Power Seat Switch Connector Remove 3. Pull the switch and bezel unit out from the seat far enough to access the switch wire harness connector. Gently pry the locking tabs of the switch away from the wire harness connector and carefully unplug the connector from the power seat switch module. 4. Remove the two screws that secure the power seat switch module to the bezel and remove the bezel. 5. Reverse the removal procedures to install. Tighten the switch mounting screws to 2.2 Nm (20 in lbs). Extended Cab 1. Disconnect and isolate the battery negative cable. 2. Remove the screw that secures the recliner lever to the recliner mechanism release shaft on the outboard side of the driver side front seat. 3. Pull the recliner lever off of the recliner mechanism release shaft. 4. Remove the three screws that secure the driver side seat cushion side shield to the outboard seat cushion frame. 5. Pull the driver side seat cushion side shield away from the seat cushion frame far enough to access the power seat switch module wire harness connector. 6. Gently pry the locking tabs of the switch away from the wire harness connector and carefully unplug the connector from the power seat switch module. 7. Remove the seat cushion side shield and power seat switch module from the seat as a unit. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Specifications > Page 664 Power Seat Switch Remove/Install - Typical 8. Remove the two screws that secure the power seat switch to the inside of the seat cushion side shield. 9. Remove the power seat switch from the seat cushion side shield. 10. Reverse the removal procedures to install. Tighten the switch mounting screws to 2.2 Nm (20 in lbs). Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Pressure Sensor/Switch > Component Information > Diagrams > With Quad Cab Connector Pin Identification Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Pressure Sensor/Switch > Component Information > Diagrams > With Quad Cab > Page 670 Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Pressure Sensor/Switch > Component Information > Diagrams > Page 671 Brake Fluid Pressure Sensor/Switch: Testing and Inspection PRESSURE DIFFERENTIAL SWITCH 1. Have helper sit in drivers seat to apply brake pedal and observe red brake warning light. 2. Raise vehicle on hoist. 3. Connect bleed hose to a rear wheel cylinder and immerse hose end in container partially filled with brake fluid. 4. Have helper press and hold brake pedal to floor and observe warning light. a. If warning light illuminates, switch is operating correctly. b. If light fails to illuminate, check circuit fuse, bulb, and wiring. The parking brake switch can be used to aid in identifying whether or not the brake light bulb and fuse is functional. Repair or replace parts as necessary and test differential pressure switch operation again. 5. If warning light still does not illuminate, switch is faulty. Replace combination valve assembly, bleed brake system and verify proper switch and valve operation. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Braking Sensor/Switch > Component Information > Locations Brake Switch Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Braking Sensor/Switch > Component Information > Diagrams > With Quad Cab Connector Pin Identification Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Braking Sensor/Switch > Component Information > Diagrams > With Quad Cab > Page 677 Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Specifications > With Four Wheel Antilock Brakes Wheel Speed Sensor: Specifications Front Bolts 11 ft.lb Rear Bolts 18 ft.lb Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Specifications > With Four Wheel Antilock Brakes > Page 682 Wheel Speed Sensor: Specifications Mounting Bolt 18 ft.lb Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Component Locations Wheel Speed Sensor: Component Locations Tone Wheel - 4x2 Wheel Speed Sensor Tone Wheel (2WD Quad Cab Typical) Wheel Speed Sensor Tone Wheel Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Component Locations > Page 685 Front Speed Sensor Mounting - 4x2 Wheel Speed Sensor - 4x4 Rear Speed Sensor Mounting Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Component Locations > Page 686 Wheel Speed Sensor: Connector Locations Left Front Wheel Speed Sensor Connector Right Front Wheel Speed Sensor Connector Rear Wheel Speed Sensor Connector Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Front Wheel Speed Sensor: Diagrams Front Connector Pin Identification Connector Pin Identification Connector Pin Identification Connector Pin Identification Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Front > Page 689 Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Front > Page 690 Wheel Speed Sensor: Diagrams Rear Connector Pin Identification Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Description and Operation > Four Wheel Antilock Brakes Wheel Speed Sensor: Description and Operation Four Wheel Antilock Brakes The ABS brake system uses 3 wheel speed sensors. A sensor is mounted to each front steering knuckles. The third sensor is mounted on top of the rear axle differential housing. The sensor is a magnet coil that is mounted over a tone wheel front/exciter ring rear with an air gap between them. The sensors measure the wheel speed by monitoring the rotation of the tone wheels front/exciter ring rear. As the teeth of the tone wheels front/exciter ring rear move through the magnetic field of the sensor an AC voltage is generated. This signal frequency increases or decreases proportionally to the speed of the wheel. The CAB monitors these signals for changes in wheel deceleration. If the CAB detects a sudden wheel or wheels deceleration within a predetermined amount the CAB will activate the ABS system. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Description and Operation > Four Wheel Antilock Brakes > Page 693 Wheel Speed Sensor: Description and Operation Rear Wheel Antilock Brakes Rear Wheel Speed Sensor And Exciter Ring Rear Wheel Speed Sensor Location The rear wheel Speed Sensor (WSS) is mounted in the rear differential housing. The WSS consists of a magnet surrounded by windings from a single strand of wire. The sensor sends a small AC signal to the Controller Antilock Brake (CAB). This signal is generated by magnetic induction. The magnetic induction is created when a toothed sensor ring (exciter ring or tone wheel) passes the stationary magnetic WSS. Exciter Ring Location The exciter ring is press fitted onto the differential carrier next to the final drive ring gear. For replacement procedure of the exciter ring, refer to Differential Assembly. See: Transmission and Drivetrain/Differential Assembly Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Description and Operation > Four Wheel Antilock Brakes > Page 694 Operation Of The Wheel Speed Sensor When the ring gear is rotated, the exciter ring passes the tip of the WSS. As the exciter ring passes the tip of the WSS, the magnetic lines of force of the sensor are cut, causing the magnetic field to be moved across the sensor's windings. This, in turn causes current to flow through the WSS circuit. Every time a tooth of the exciter ring passes the tip of the WSS, an AC signal is generated. Each AC signal (positive to negative signal or sinewave) is interpreted by the CAB. It then compares the frequency of the sinewave to a time value to calculate vehicle speed. The CAB continues to monitor the frequency to determine a deceleration rate that would indicate a possible wheel-locking tendency. The signal strength of any magnetic induction sensor is directly affected by: - Magnetic field strength; the stronger the magnetic field, the stronger the signal. - Number of windings in the sensor; more windings provide a stronger signal. - Exciter ring speed; the faster the exciter ring rotates, the stronger the signal will be. - Distance between the exciter ring teeth and WSS; the closer the WSS is to the exciter ring, the stronger the signal will be. The rear WSS is not adjustable. A clearance specification has been established for manufacturing tolerances. If the clearance is not within these specifications, then either the WSS or other components may be damaged. The clearance between the WSS and the exciter ring is 0.005 0.050 in. Data Link Connector - Typical The assembly plant performs a "Rolls Test" on every vehicle that leaves the assembly plant. One of the test performed is a test of the WSS. To properly test the sensor, the assembly plant connects test equipment to the Data Link Connector (DLC). This connector is located to the right of the steering column and attached to the lower portion of the instrument panel. The rolls test terminal is spliced to the WSS circuit. The vehicle is then driven on a set of rollers and the WSS output is monitored for proper operation. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor Replacement Wheel Speed Sensor: Service and Repair Wheel Speed Sensor Replacement Front REMOVAL 1. Raise and support vehicle. 2. Remove wheel and tire assembly. 3. Disconnect the ABS wheel speed sensor wire from under the hood. Remove sensor wire from the frame and steering knuckle. 4. Remove brake caliper. 5. Remove rotor on models with 5 wheel studs. On models with 8 studs remove rotor hub bearing assembly and separate the rotor from the hub bearing. Wheel Speed Sensor - 4x4 6. Remove bolt attaching sensor to the hub bearing. 7. Remove sensor and wire. INSTALLATION 1. Install the sensor in the hub bearing and tighten the bolt to 14 Nm (11 ft. lbs.). Use original or replacement sensor bolts only. The bolts are special and must not be substituted. 2. Install the rotor on models with 5 wheel studs. On models with 8 studs install the rotor on the hub bearing and install the assembly on the knuckle. 3. Install sensor wire to the steering knuckle and frame. Connect the wheel speed sensor wire under the hood. 4. Check sensor wire routing. Be sure wire is clear of all chassis components and is not twisted or kinked at any spot. 5. Install brake caliper. 6. Install wheel and tire assemblies. 7. Remove support and lower the vehicle. 8. Apply brakes several times to seat brake shoes and caliper piston. Do not move vehicle until firm brake pedal is obtained. 9. Verify sensor operation with scan tool. With Rear Wheel Antilock Brakes REMOVAL 1. Raise vehicle on hoist. 2. Remove brake line mounting nut and remove the brake line from the sensor stud. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor Replacement > Page 697 Rear Speed Sensor Mounting 3. Remove mounting stud from the sensor and shield. 4. Remove sensor and shield from differential housing. 5. Disconnect sensor wire harness and remove sensor. INSTALLATION 1. Connect harness to sensor. Be sure seal is securely in place between sensor and wiring connector. 2. Install O-ring on sensor (if removed). 3. Insert sensor in differential housing. 4. Install sensor shield. 5. Install the sensor mounting stud and tighten to 24 Nm (18 ft. lbs.). 6. Install the brake line on the sensor stud and install the nut. 7. Lower vehicle. With Four Wheel Antilock Brakes REMOVAL 1. Raise vehicle on hoist. 2. Remove brake line mounting nut and remove the brake line from the sensor stud. Rear Speed Sensor Mounting 3. Remove mounting stud from the sensor and shield. 4. Remove sensor and shield from differential housing. 5. Disconnect sensor wire harness and remove sensor. INSTALLATION 1. Connect harness to sensor. Be sure seal is securely in place between sensor and wiring connector. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor Replacement > Page 698 2. Install O-ring on sensor (if removed). 3. Insert sensor in differential housing. 4. Install sensor shield. 5. Install the sensor mounting stud and tighten to 24 Nm (18 ft. lbs.). 6. Install the brake line on the sensor stud and install the nut. 7. Lower vehicle. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor Replacement > Page 699 Wheel Speed Sensor: Service and Repair Tone Wheel Replacement Front Tone Wheel Tone Wheel - 4x2 The tone wheel for the front speed sensor is located in the rotor hub on 4x2 models. On 4x4 models, the tone wheel is located in the hub/bearing housing. The tone wheel is not a serviceable component. On 4x2 models, the complete rotor and hub assembly will have to be replaced if the tone wheel is damaged. On 4x4 models, the hub/bearing must be replaced, if the tone wheel is damaged. Rear Tone Wheel The toothed exciter ring is press-fitted onto the differential carrier next to the final drive ring gear in the differential case. If the ring is damaged, refer to Differential Assembly for service procedures. See: Transmission and Drivetrain/Differential Assembly Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications Coolant Temperature Sensor/Switch (For Computer): Specifications Engine Coolant Temperature(ECT) Sensor 14 Nm Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 705 Coolant Temperature Sensor/Switch (For Computer): Locations Engine Coolant Temperature Sensor The engine coolant temperature sensor is installed into the front of the cylinder head near to the thermostat housing and protrudes into a water jacket. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 706 Connector View Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 707 Coolant Temperature Sensor/Switch (For Computer): Description and Operation ENGINE COOLANT TEMPERATURE (ECT) SENSOR-ECM INPUT Engine Coolant Temperature Sensor The engine coolant temperature sensor is installed into the front of the cylinder head near to the thermostat housing and protrudes into a water jacket. The sensor provides an input voltage to the Engine Control Module (ECM) to monitor coolant temperature. The ECM uses this input along with inputs from other sensors for engine protection, fuel timing and fuel control. As coolant temperature varies, the coolant temperature sensor resistance will change. This change in resistance results in a different input voltage to the ECM. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 708 Coolant Temperature Sensor/Switch (For Computer): Service and Repair ECT Sensor Location The Engine Coolant Temperature (ECT) sensor is located at the front of the cylinder head near the thermostat. REMOVAL WARNING: THE COOLING SYSTEM MAY BE UNDER PRESSURE. HOT COOLANT CAN CAUSE BURNS. 1. Partially drain cooling system until coolant level is below cylinder head. 2. Disconnect ECT sensor electrical connector from sensor. ECT Sensor Removal/Installation 3. Remove ECT sensor from cylinder head. 4. Discard sensor O-ring. INSTALLATION 1. Clean sensor mounting hole of rust or contaminants. 2. Install new O-ring to sensor. Apply clean engine oil to sensor O-ring and sensor threads. 3. Install ECT sensor into cylinder head. Tighten to 14 Nm (10 ft. lbs.) torque. 4. Connect sensor electrical connector. 5. fill cooling system and check for coolant leaks. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Specifications Cruise Control Switch: Specifications Tighten mounting screws to 3 N.m (26 in lbs +/- 2 in lbs) torque. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Specifications > Page 713 Speed Control Switches (2), Mounting Screws (2) Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Diagrams > Left Speed Control Switch - 2 Way Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Diagrams > Left Speed Control Switch - 2 Way > Page 716 Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Diagrams > Page 717 Cruise Control Switch: Service Precautions WARNING: BEFORE BEGINNING ANY AIR BAG SYSTEM COMPONENT REMOVAL OR INSTALLATION, REMOVE AND ISOLATE THE NEGATIVE (-) CABLE(S) FROM THE BATTERY. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. THEN WAIT TWO MINUTES FOR SYSTEM CAPACITOR TO DISCHARGE BEFORE FURTHER SYSTEM SERVICE. FAILURE TO DO THIS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE INJURY . Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Diagrams > Page 718 Cruise Control Switch: Description and Operation SYSTEM OPERATION Two separate speed control switch modules are mounted on the steering wheel to the left and right side of the driver's airbag module. Within the two switch modules, five momentary contact switches, supporting seven different speed control functions are used. The outputs from these switches are filtered into one input. The Powertrain Control Module (PCM) determines which output has been applied through resistive multiplexing. The input circuit voltage is measured by the PCM to determine which switch function has been selected. A speed control indicator lamp, located on the instrument panel cluster is energized by the PCM via the CCD Bus. This occurs when speed control system power has been turned ON, and the engine is running. The two switch modules are labeled: ON/OFF, SET, RESUME/ACCEL, CANCEL and COAST. Refer to the owner's manual for more information on speed control switch functions and setting procedures. The individual switches cannot be repaired. If one individual switch fails, the switch module must be replaced. SPEED CONTROL SWITCHES-PCM INPUT Six different speed control functions, using three momentary contact switches, are monitored through this multiplexed input. The resistance monitored at this input, in combination with the length of time the PCM measures the resistance, determines which switch feature has been selected. The three switches are: On/Off; Set/Coast, Cancel and Resume/Accelerate. Refer to Vehicle Speed Control System for further speed control information. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Diagrams > Page 719 Cruise Control Switch: Service and Repair Speed Control Switches WARNING: BEFORE BEGINNING ANY AIR BAG SYSTEM COMPONENT REMOVAL OR INSTALLATION, REMOVE AND ISOLATE THE NEGATIVE (-) CABLE(S) FROM THE BATTERY. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. THEN WAIT TWO MINUTES FOR SYSTEM CAPACITOR TO DISCHARGE BEFORE FURTHER SYSTEM SERVICE. FAILURE TO DO THIS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE INJURY. REMOVAL 1. Disconnect and isolate negative battery cable(s). 2. Remove airbag module. Refer to Passive Restraint Systems for procedures. 3. Remove switch-to-steering wheel mounting screws. 4. Remove switch. 5. Remove electrical connector at switch. INSTALLATION 1. Install electrical connector to switch. 2. Install switch and mounting screws. 3. Tighten screws to 3 N.m (26 in lbs +/- 2 in lbs) torque. 4. Install airbag module. Refer to Passive Restraint Systems for procedures. 5. Connect negative battery cable(s). Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Vehicle Speed Sensor/Transducer - Cruise Control > Component Information > Description and Operation Vehicle Speed Sensor/Transducer - Cruise Control: Description and Operation The Vehicle Speed Sensor (VSS) is no longer used for any Dodge Truck. Vehicle speed and distance covered are measured by the Rear Wheel Speed Sensor. The sensor is mounted to the rear axle. A signal is sent from this sensor to the Controller Antilock Brake (CAB) computer. A signal is then sent from the CAB to the Powertrain Control Module (PCM) to determine vehicle speed and distance covered. The PCM will then determine strategies for speed control system operation. Testing for the Rear Wheel Speed Sensor can be found at Antilock Brakes / Traction Control Systems. See: Brakes and Traction Control/Antilock Brakes / Traction Control Systems/Testing and Inspection All other testing for the Vehicle Speed Signal can be found at Computers and Control Systems. See: Powertrain Management/Computers and Control Systems/Testing and Inspection Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations Engine Oil Pressure Sensor, Electrical Connector Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations > Page 727 Connector View Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations > Page 728 Oil Pressure Sender: Testing and Inspection For Oil Pressure Testing, refer to Powertrain Management/Computers and Controls/Testing and Inspection/Procedures/Driveability (DR) Tests. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Specifications Oil Pressure Sensor: Specifications Oil Pressure Sender/Switch 12 ft.lb Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Specifications > Page 732 Oil Pressure Sensor: Locations Oil Pressure Sensor (Engine) Location The oil pressure sensor is installed into the oil pressure galley on the engine block. It is located below and to the rear of the ECM. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Specifications > Page 733 Oil Pressure Sensor: Diagrams Engine Oil Pressure Sensor - 3 Way Engine Oil Pressure Sensor (Diesel) - 3 Way Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Specifications > Page 734 Oil Pressure Sensor: Description and Operation A signal is sent from the engine oil pressure sensor (sending unit) to the Engine Control Module (ECM) relating to engine oil pressure. The ECM monitors this signal and converts it to a pressure value. This value is used by the ECM for the engine protection system. The pressure signal from the ECM is bussed to the instrument panel oil gauge/lamp via the CCD circuits. Oil Pressure Sensor (Engine) Location The oil pressure sensor is installed into the oil pressure galley on the engine block. It is located below and to the rear of the ECM. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Specifications > Page 735 Oil Pressure Sensor: Service and Repair REMOVAL 1. Disconnect the battery negative cables. Oil Pressure Sensor Location 2. Disconnect the oil pressure sensor connector. 3. Using a suitable socket, remove the oil pressure sensor from the block (counter-clockwise). INSTALLATION Oil Pressure Sensor And O-Ring 1. If the sensor is not being replaced, inspect the O-ring and replace if necessary. 2. Install the oil pressure sensor and tighten to 16 Nm (144 inch lbs.) torque. 3. Connect the battery negative cables. 4. Start engine and check for oil leaks at the sensor. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Specifications Ambient Temperature Sensor / Switch HVAC: Specifications Tighten the one screw that secures the ambient temperature sensor bracket to the inner hood reinforcement to 5.6 Nm (50 in lbs). Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Specifications > Page 740 Ambient Temperature Sensor / Switch HVAC: Locations Ambient Temperature Sensor Remove/Install The ambient temperature sensor is a variable resistor mounted to a bracket that is secured with a screw to the underside of the hood panel near the hood latch striker in the engine compartment. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Specifications > Page 741 Ambient Temperature Sensor / Switch HVAC: Diagrams Ambient Temperature Sensor Ambient Temperature Sensor - 2 Way Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Specifications > Page 742 Ambient Temperature Sensor / Switch HVAC: Description and Operation DESCRIPTION Ambient air temperature is monitored by the compass mini-trip computer module through the ambient temperature sensor. The ambient temperature sensor is a variable resistor mounted to a bracket that is secured with a screw to the underside of the hood panel near the hood latch striker in the engine compartment. The ambient temperature sensor cannot be adjusted or repaired and, if faulty or damaged, it must be replaced. OPERATION The ambient temperature sensor is a variable resistor that operates on a five volt reference signal sent to it by the compass mini-trip computer module. The resistance in the sensor changes as temperature changes, changing the return circuit voltage to the compass mini-trip computer module. Based upon the resistance in the sensor, the compass mini-trip computer module senses a specific voltage on the return circuit, which it is programmed to correspond to a specific temperature. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Specifications > Page 743 Ambient Temperature Sensor / Switch HVAC: Testing and Inspection The thermometer function is supported by the ambient temperature sensor, a wiring circuit, and a portion of the compass mini-trip computer module. If any portion of the ambient temperature sensor circuit fails, the compass/thermometer display function will self-diagnose the circuit. An "SC" (short circuit) will appear in the display in place of the temperature, when the sensor is exposed to temperatures above 55° C (131° F), or if the sensor circuit is shorted. An "OC" (open circuit) will appear in the display in place of the temperature, when the sensor is exposed to temperatures below -40° C (-40° F), or if the sensor circuit is open. The ambient temperature sensor circuit can also be diagnosed using the following Sensor Test, and Sensor Circuit Test. If the temperature sensor and circuit are confirmed to be OK, but the temperature display is inoperative or incorrect, refer to Compass Mini-Trip Computer in the Diagnosis and Testing. Sensor Test 1. Turn the ignition switch to the Off position. Disconnect and isolate the battery negative cable. Disconnect the ambient temperature sensor wire harness connector. 2. Measure the resistance of the ambient temperature sensor. At -40° C (-40° F), the sensor resistance is 336 K Ohms. At 55° C (131° F), the sensor resistance is 2.488 K Ohms. The sensor resistance should read between these two values. If OK, refer to Sensor Circuit Test in the Diagnosis and Testing. If not OK, replace the faulty ambient temperature sensor. Sensor Circuit Test 1. Turn the ignition switch to the Off position. Disconnect and isolate the battery negative cable. Disconnect the ambient temperature sensor wire harness connector and the overhead console wire harness connector. 2. Connect a jumper wire between the two terminals in the body half of the ambient temperature sensor wire harness connector. 3. Check for continuity between the sensor return circuit and the ambient temperature sensor signal circuit cavities of the roof wire harness overhead console connector. There should be continuity. If OK, go to Step 4. If not OK, repair the open sensor return circuit or ambient temperature sensor signal circuit to the ambient temperature sensor as required. 4. Remove the jumper wire from the body half of the ambient temperature sensor wire harness connector. Check for continuity between the sensor return circuit cavity of the roof wire harness overhead console connector and a good ground. There should be no continuity. If OK, go to Step 5. If not OK, repair the shorted sensor return circuit as required. 5. Check for continuity between the ambient temperature sensor signal circuit cavity of the roof wire harness overhead console connector and a good ground. There should be no continuity. If OK, refer to Compass Mini-Trip Computer in the Diagnosis and Testing. If not OK, repair the shorted ambient temperature sensor signal circuit as required. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Specifications > Page 744 Ambient Temperature Sensor / Switch HVAC: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. Ambient Temperature Sensor Remove/Install 2. Locate the ambient temperature sensor, on the underside of the hood near the hood latch striker. 3. Disconnect the wire harness connector from the ambient temperature sensor connector receptacle. 4. Remove the one screw that secures the ambient temperature sensor bracket to the inner hood reinforcement. 5. Remove the ambient temperature sensor from the inner hood reinforcement. INSTALLATION 1. Position the ambient temperature sensor onto the inner hood reinforcement. 2. Install and tighten the one screw that secures the ambient temperature sensor bracket to the inner hood reinforcement. Tighten the screw to 5.6 Nm (50 in lbs). 3. Reconnect the wire harness connector to the ambient temperature sensor connector receptacle. 4. Reconnect the battery negative cable. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Locations Blower Motor Switch: Locations The blower motor switch is mounted in the heater-A/C control panel. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Locations > Page 748 Blower Motor Switch: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO RESTRAINT SYSTEMS / AIR BAG SYSTEMS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY . Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Locations > Page 749 Blower Motor Switch: Description and Operation SYSTEM OPERATION The heater-only or heater-A/C blower motor is controlled by a four position rotary-type blower motor switch, mounted in the heater-A/C control panel. The switch allows the selection of one of four blower motor speeds, but can only be turned off by selecting the Off position with the heater-A/C mode control switch knob. The blower motor switch directs the blower motor ground path through the mode control switch to the blower motor resistor, or directly to ground, as required to achieve the selected blower motor speed. The blower motor switch cannot be repaired and, if faulty or damaged, the entire heater-only or heater-A/C control unit must be replaced. The blower motor switch knob is serviced separately. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Locations > Page 750 Blower Motor Switch: Testing and Inspection WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIR BAGS AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Check for battery voltage at the fuse in the Power Distribution Center (PDC). If OK, go to Step 2. If not OK, repair the shorted circuit or component as required and replace the faulty fuse. 2. Turn the ignition switch to the Off position. Disconnect and isolate the battery negative cable. Remove the heater-A/C control from the instrument panel. Check for continuity between the ground circuit cavity of the heater-A/C control wire harness connector and a good ground. There should be continuity. If OK, go to Step 3. If not OK, repair the open circuit to ground as required. 3. With the heater-A/C control wire harness connector unplugged, place the heater-A/C mode control switch knob in any position except the Off position. Check for continuity between the ground circuit terminal and each of the blower motor driver circuit terminals of the heater-A/C control as you move the blower motor switch knob to each of the four speed positions. There should be continuity at each driver circuit terminal in only one blower motor switch speed position. If OK, test and repair the blower driver circuits between the heater-A/C control connector and the blower motor resistor as required. If not OK, replace the faulty heater-A/C control unit. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > High Pressure Sensor / Switch, HVAC > Component Information > Locations High Pressure Sensor / Switch: Locations Suction And Discharge Line Remove/Install The high pressure cut-off switch is located on the discharge line near the compressor. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > High Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 755 High Pressure Sensor / Switch: Description and Operation SYSTEM OPERATION High Pressure Cut-off Switch The high pressure cut-off switch is located on the discharge line near the compressor. The switch is screwed onto a fitting that contains a Schrader-type valve, which allows the switch to be serviced without discharging the refrigerant system. The discharge line fitting is equipped with an O-ring to seal the switch connection. The high pressure cut-off switch is connected in series electrically with the low pressure cycling clutch switch between ground and the Powertrain Control Module (PCM). The switch contacts open and close causing the PCM to turn the compressor clutch on and off. This prevents compressor operation when the discharge line pressure approaches high levels. The high pressure cut-off switch contacts are open when the discharge line pressure rises above about 3100 to 3375 kPa (450 to 490 psi). The switch contacts will close when the discharge line pressure drops to about 1860 to 2275 kPa (270 to 330 psi). When checking refrigerant system pressures with a manifold gauge set, keep in mind that the indicated pressures will be about 172 kPa (25 psi) below the actual switch pressure values due to the pressure drop that occurs in the refrigerant system between the switch and the high pressure service port. The high pressure cut-off switch is a factory-calibrated unit. The switch cannot be adjusted or repaired and, if faulty or damaged, it must be replaced. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > High Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 756 High Pressure Sensor / Switch: Testing and Inspection Before performing diagnosis of the high pressure cut-off switch, verify that the refrigerant system has the correct refrigerant charge. See Refrigerant System Charge in the Service Procedures for more information. 1. Disconnect and isolate the battery negative cable. 2. Unplug the high pressure cut-off switch wire harness connector from the switch on the refrigerant system fitting. 3. Check for continuity between the two terminals of the high pressure cut-off switch. There should be continuity If OK, test and repair the A/C switch sense circuit as required. If not OK, replace the faulty switch. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > High Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 757 High Pressure Sensor / Switch: Service and Repair High Pressure Cut-Off Switch Remove/Install REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Unplug the wire harness connector from the high pressure cut-off switch, which is mounted to a fitting on the discharge line between the compressor and the condenser inlet. 3. Unscrew the high pressure cut-off switch from the discharge line fitting. 4. Remove the high pressure cut-off switch from the vehicle. 5. Remove the O-ring seal from the discharge line fitting and discard. INSTALLATION 1. Lubricate a new O-ring seal with clean refrigerant oil and install it on the discharge line fitting. Use only the specified O-rings as they are made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the compressor in the vehicle. 2. Install and tighten the high pressure cut-off switch on the discharge line fitting. 3. Plug the wire harness connector into the high pressure cut-off switch. 4. Connect the battery negative cable. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Specifications Low Pressure Sensor / Switch: Specifications Switch contacts are open when the suction pressure is about 172 kPa (25 psi) or lower Switch contacts close when the suction pressure rises to about 296 kPa (43 psi) or above. Lower ambient temperatures, below about -1° C (30° F), will also cause the switch contacts to open. This is due to the pressure/temperature relationship of the refrigerant in the system. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Specifications > Page 761 Low Pressure Sensor / Switch: Locations Accumulator And Low Pressure Cycling Clutch Switch The low pressure cycling clutch switch is located on the top of the accumulator. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Specifications > Page 762 Low Pressure Sensor / Switch: Description and Operation Accumulator And Low Pressure Cycling Clutch Switch SYSTEM OPERATION Low Pressure Cycling Clutch Switch The low pressure cycling clutch switch is located on the top of the accumulator. The switch is screwed onto an accumulator fitting that contains a Schrader type valve, which allows the switch to be serviced without discharging the refrigerant system. The accumulator fitting is equipped with an O-ring to seal the switch connection. The low pressure cycling clutch switch is connected in series electrically with the high pressure cut-off switch and the heater-A/C controls, between ground and the Powertrain Control Module (PCM). The switch contacts open and close causing the PCM to turn the compressor clutch on and off. This regulates the refrigerant system pressure and controls evaporator temperature. Controlling evaporator temperature prevents condensate water on the evaporator fins from freezing and obstructing air conditioning system air flow. The low pressure cycling clutch switch contacts are open when the suction pressure is about 172 kPa (25 psi) or lower. The switch contacts will close when the suction pressure rises to about 296 kPa (43 psi) or above. Lower ambient temperatures, below about -1° C (30° F), will also cause the switch contacts to open. This is due to the pressure/temperature relationship of the refrigerant in the system. The low pressure cycling clutch switch is a factory calibrated unit. It cannot be adjusted or repaired and, if faulty or damaged, it must be replaced. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Specifications > Page 763 Low Pressure Sensor / Switch: Testing and Inspection Accumulator And Low Pressure Cycling Clutch Switch Low Pressure Cycling Clutch Switch Before performing diagnosis of the low pressure cycling clutch switch, be certain that the switch is properly installed on the accumulator fitting. If the switch is too loose it may not open the Schrader-type valve in the accumulator fitting, which will prevent the switch from correctly monitoring the refrigerant system pressure. Also verify that the refrigerant system has the correct refrigerant charge. See Refrigerant System Charge in the Service Procedures for more information. Remember that lower ambient temperatures, below about -1° C (30° F), during cold weather will open the switch contacts and prevent compressor operation due to the pressure/temperature relationship of the refrigerant. 1. Disconnect and isolate the battery negative cable. 2. Unplug the low pressure cycling clutch switch wire harness connector from the switch on the accumulator fitting. 3. Install a jumper wire between the two cavities of the low pressure cycling clutch switch wire harness connector. 4. Connect a manifold gauge set to the refrigerant system service ports. See Refrigerant System Service Equipment and Refrigerant System Service Ports in the Description and Operation for more information. 5. Connect the battery negative cable. 6. Place the heater-A/C mode control switch knob in any A/C position and start the engine. 7. Check for continuity between the two terminals of the low pressure cycling clutch switch. There should be continuity with a suction pressure reading of 296 kPa (43 psi) or above, and no continuity with a suction pressure reading of 172 kPa (25 psi) or below. If OK, test and repair the A/C switch sense circuit as required. If not OK, replace the faulty switch. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Specifications > Page 764 Low Pressure Sensor / Switch: Service and Repair Accumulator And Low Pressure Cycling Clutch Switch REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Unplug the wire harness connector from the low pressure cycling clutch switch on the top of the accumulator. 3. Unscrew the low pressure cycling clutch switch from the fitting on the top of the accumulator. 4. Remove the O-ring seal from the accumulator fitting and discard. INSTALLATION 1. Lubricate a new O-ring seal with clean refrigerant oil and install it on the accumulator fitting. Use only the specified O-rings as they are made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the compressor in the vehicle. 2. Install and tighten the low pressure cycling clutch switch on the accumulator fitting. The switch should be hand-tightened onto the accumulator fitting. 3. Plug the wire harness connector into the low pressure cycling clutch switch. 4. Connect the battery negative cable. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions Dimmer Switch: Diagram Information and Instructions Introduction General Information (Part 1 Of 2) Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 770 General Information (Part 2 Of 2) Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Function Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 771 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 772 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 773 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 774 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 775 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 776 Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 777 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 778 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 779 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 780 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 781 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Terminal/Connector Repair-Thomas and Betts Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 782 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector. Removing Wire Terminal 4. Insert the probe end of Special Tool 6934 into the back of the connector cavity. 5. Grasp the wire and Special Tool 6934 and slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal. 7. Install the wire and terminal in the connector. Fully seat the terminal in the connector. Single Lock Tab 8. Push in the single lock tab on the side of the connector. Wiring Repair Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 783 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 784 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 785 Dimmer Switch: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 786 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 787 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 788 Multi-Function Switch - 24 Way Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions Door Switch: Diagram Information and Instructions Introduction General Information (Part 1 Of 2) Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 793 General Information (Part 2 Of 2) Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Function Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 794 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 795 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 796 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 797 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 798 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 799 Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 800 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 801 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 802 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 803 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 804 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Terminal/Connector Repair-Thomas and Betts Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 805 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector. Removing Wire Terminal 4. Insert the probe end of Special Tool 6934 into the back of the connector cavity. 5. Grasp the wire and Special Tool 6934 and slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal. 7. Install the wire and terminal in the connector. Fully seat the terminal in the connector. Single Lock Tab 8. Push in the single lock tab on the side of the connector. Wiring Repair Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 806 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 807 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 808 Door Switch: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 809 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 810 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 811 Door Switch: Connector Views Driver Door Jamb Switch (CTM) - Natural 2 Way Passenger Door Jamb Switch - Natural 3 Way Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 08-42-99 > Dec > 99 > Fuel Gauge - Reads Full for an Excessive Time Fuel Gauge Sender: Customer Interest Fuel Gauge - Reads Full for an Excessive Time NUMBER: 08-42-99 GROUP: Electrical DATE: Dec. 17, 1999 SUBJECT: The Fuel Gauge Reads Full For An Excessive Period Of Time OVERVIEW: This bulletin involves installing a new fuel pump module. MODELS: 1998 - 1999 (BR/BE) Ram Truck NOTE: THIS BULLETIN APPLIES TO VEHICLE EQUIPPED WITH THE 5.9L CUMMINS DIESEL ENGINE. SYMPTOM/CONDITION: After driving over 200 miles, the fuel gauge may read full until the vehicle travels over a bump in the road and then the gauge operates normally. DIAGNOSIS: This condition may be caused by the float in the fuel pump module sticking and may be difficult to diagnose. Perform the repair procedure if the customer's concern matches the description identified in the Symptom/Condition. PARTS REQUIRED: 1 04897668AE Module, Fuel Pump REPAIR PROCEDURE: 1. Using the procedure identified in the 1999 Ram Truck Service Manual (Publication No. 81-370-9108), page 14-92, replace the fuel pump module with p/n 04897668AE. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 14-50-05-90 1.3 Hrs. FAILURE CODE: P8 - New Part Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 08-42-99 > Dec > 99 > Fuel Gauge - Reads Full for an Excessive Time Fuel Gauge Sender: All Technical Service Bulletins Fuel Gauge - Reads Full for an Excessive Time NUMBER: 08-42-99 GROUP: Electrical DATE: Dec. 17, 1999 SUBJECT: The Fuel Gauge Reads Full For An Excessive Period Of Time OVERVIEW: This bulletin involves installing a new fuel pump module. MODELS: 1998 - 1999 (BR/BE) Ram Truck NOTE: THIS BULLETIN APPLIES TO VEHICLE EQUIPPED WITH THE 5.9L CUMMINS DIESEL ENGINE. SYMPTOM/CONDITION: After driving over 200 miles, the fuel gauge may read full until the vehicle travels over a bump in the road and then the gauge operates normally. DIAGNOSIS: This condition may be caused by the float in the fuel pump module sticking and may be difficult to diagnose. Perform the repair procedure if the customer's concern matches the description identified in the Symptom/Condition. PARTS REQUIRED: 1 04897668AE Module, Fuel Pump REPAIR PROCEDURE: 1. Using the procedure identified in the 1999 Ram Truck Service Manual (Publication No. 81-370-9108), page 14-92, replace the fuel pump module with p/n 04897668AE. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 14-50-05-90 1.3 Hrs. FAILURE CODE: P8 - New Part Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Page 825 Fuel Gauge Sender: Specifications Fuel Pump Module Locknut 24-44 Nm Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Page 826 Fuel Tank Module, Rollover Valve Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Page 827 Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Page 828 Fuel Gauge Sender: Description and Operation FUEL GAUGE SENDING UNIT The fuel gauge sending unit (fuel level sensor) is attached to the side of the fuel tank module. The sending unit consists of a float, an arm, and a variable resistor (track). The resistor track is used to send electrical signals to the powertrain Control Module (PCM) for fuel gauge operation. After this signal is sent to the PCM, the PCM will transmit the data across the CCD bus circuits to the instrument panel. Here it is translated into the appropriate fuel gauge level reading. As fuel level increases, the float and arm move up. This decreases the sending unit resistance, causing the fuel gauge to read full. As fuel level decreases, the float and arm move down. This increases the sending unit resistance causing the fuel gauge to read empty. FUEL TANK MODULE An electric fuel pump is not used in the fuel tank module for diesel powered engines. Fuel is supplied by the engine mounted fuel transfer pump and the fuel injection pump. Top View Of Fuel Tank Module The fuel tank module is installed in the top of the fuel tank. The fuel tank module contains the following components: Fuel reservoir - A separate in-tank fuel filter - Rollover valve - Fuel gauge sending unit (fuel level sensor) - Fuel supply line connection - Fuel return line connection - Auxiliary non-pressurized fuel supply fitting Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Page 829 Fuel Gauge Sender: Service and Repair REMOVAL 1. Drain and remove fuel tank. Refer to Fuel Tank Removal/Installation. 2. Thoroughly clean area around tank module at top of tank. Locknut Removal/Installation - Typical Module 3. The plastic fuel tank module locknut is threaded onto fuel tank. Install Special Tool 6856 to locknut and remove locknut. The fuel tank module will spring up when locknut is removed. 4. Remove module from fuel tank. INSTALLATION CAUTION: Whenever the fuel tank module is serviced, the rubber gasket must be replaced. 1. Thoroughly clean locknut and locknut threads at top of tank. 2. Using new gasket, carefully position fuel tank module into opening in fuel tank. 3. Position locknut over top of fuel tank module. Install locknut finger tight. 4. When looking down at tank from drivers side of tank, the arrow at top of module should be aligned between two marks stamped into tank (approximately 2 o'clock position). The fuel line connectors, roll over valve and fuel gauge electrical connector should all be pointed to drivers side of vehicle. Rotate and align module/tank marks if necessary before tightening locknut. This step must be performed to prevent the module's float from contacting side of fuel tank. 5. Tighten locknut to 24-44 Nm (18-32 ft. lbs.) torque. 6. Install fuel tank. Refer to Fuel Tank Removal/ Installation. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Water In Fuel Sensor > Component Information > Technical Service Bulletins > Water In Fuel Sensor Probe - Maintenance Water In Fuel Sensor: Technical Service Bulletins Water In Fuel Sensor Probe - Maintenance NUMBER: 14-03-00 GROUP: Fuel DATE: April 14, 2000 SUBJECT: Maintenance To The Water-In-Fuel Sensor Probes Due To Possible Fuel Contamination MODELS: 1998 - 2001 (BR/BE) Ram Truck NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 5.9L - 24V DIESEL ENGINE. DISCUSSION: The probes on the end of the Water-In-Fuel (WIF) sensor may become less effective at sensing the presence of water in the fuel if they are exposed to contaminated fuel. Contaminant from the fuel may insulate the WIF sensor probes and inhibit the WIF lamp from illuminating when water is present. Figure 1 Any time service is performed on the fuel filter or fuel filter housing, the probes on the end of the Water-In-Fuel sensor should be cleaned. Use a clean cloth to wipe the WIF probes of any contaminant (Figure 1). Two designs of the fuel filter housing have been placed in service. Though the designs are different, cleaning the WIF sensor probes remain basically the same. POLICY: Information Only Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Water In Fuel Sensor > Component Information > Technical Service Bulletins > Page 834 Water In Fuel Sensor: Locations Water-In-Fuel Sensor Location The Water-In-Fuel (WIF) sensor is located at the side of fuel filter/water separator canister. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Water In Fuel Sensor > Component Information > Technical Service Bulletins > Page 835 Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Water In Fuel Sensor > Component Information > Technical Service Bulletins > Page 836 Water In Fuel Sensor: Description and Operation WATER-IN-FUEL (WIF) SENSOR-ECM INPUT The sensor sends an input to the Engine Control Module (ECM) when it senses water in the fuel filter water separator. As the water level in the filter/separator increases, the resistance across the WIF sensor decreases. This decrease in resistance is sent as a signal to the ECM and compared to a high water standard value. Once the value reaches 30 to 40 kilohms, the ECM will activate the water-in-fuel warning lamp through CCD bus circuits. This all takes place when the ignition key is initially put in the ON position. The ECM continues to monitor the input at the end of the intake manifold air heater post-heat cycle. Water-In-Fuel Sensor Location The WIF sensor is located at the bottom of the fuel filter/water separator canister. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Water In Fuel Sensor > Component Information > Technical Service Bulletins > Page 837 Water In Fuel Sensor: Service and Repair The Water-In-Fuel (WIF) sensor is located at the side of fuel filter/water separator canister. Refer to Fuel Filter-Water Separator Removal/Installation for WIF sensor removal/installation procedures. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Specifications Backup Lamp Switch: Specifications Back-up Lamp Switch 20 ft.lb Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Specifications > Page 842 Transmission Connectors Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions Backup Lamp Switch: Diagram Information and Instructions Introduction General Information (Part 1 Of 2) Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 845 General Information (Part 2 Of 2) Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Function Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 846 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 847 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 848 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 849 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 850 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 851 Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 852 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 853 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 854 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 855 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 856 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Terminal/Connector Repair-Thomas and Betts Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 857 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector. Removing Wire Terminal 4. Insert the probe end of Special Tool 6934 into the back of the connector cavity. 5. Grasp the wire and Special Tool 6934 and slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal. 7. Install the wire and terminal in the connector. Fully seat the terminal in the connector. Single Lock Tab 8. Push in the single lock tab on the side of the connector. Wiring Repair Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 858 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 859 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 860 Backup Lamp Switch: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 861 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 862 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 863 8w-51-2 Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Page 864 Backup Lamp Switch: Service and Repair Removal 1. Disengage wiring connector from the backup lamp switch. Backup Lamp Switch 2. Remove the backup lamp switch from the extension/adapter housing. Be sure to remove the switch gasket from the housing. Installation 1. Remove any remaining gasket material from the extension/adapter housing. 2. Install switch and gasket into the extension/ adapter housing. 3. 1brque the backup lamp switch to 20 - 35 Nm (20 28 ft. lbs.). Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > Engine/Lighting - Stoplamp Switch/Vacuum Pump Rev. Brake Light Switch: Technical Service Bulletins Engine/Lighting - Stoplamp Switch/Vacuum Pump Rev. NUMBER: 26-12-98B GROUP: Miscellaneous DATE: December, 1998 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1999 Ram Truck Service Manual - Publication Number 81-370-9108 DESCRIPTION OF CHANGES Revision to the stop lamp switch service procedures Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > Engine/Lighting - Stoplamp Switch/Vacuum Pump Rev. > Page 869 5-2 Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > Engine/Lighting - Stoplamp Switch/Vacuum Pump Rev. > Page 870 5-10 Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > Engine/Lighting - Stoplamp Switch/Vacuum Pump Rev. > Page 871 5-17 Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > Engine/Lighting - Stoplamp Switch/Vacuum Pump Rev. > Page 872 5-18 Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > Engine/Lighting - Stoplamp Switch/Vacuum Pump Rev. > Page 873 5-40 Revision to the vacuum pump service procedures Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > Engine/Lighting - Stoplamp Switch/Vacuum Pump Rev. > Page 874 9-238 Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > Engine/Lighting - Stoplamp Switch/Vacuum Pump Rev. > Page 875 9-239 Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > Engine/Lighting - Stoplamp Switch/Vacuum Pump Rev. > Page 876 9-240 Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > Page 877 Brake Light Switch: Locations The switch is mounted on the brake pedal mounting bracket under the instrument panel. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > Page 878 Brake Lamp Switch Connector Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Description and Operation > General Information Brake Light Switch: Description and Operation General Information The content of this article reflects changes called for in TSB 26-12-98. The plunger type stop lamp switch is mounted on a bracket attached to the brake pedal support. The switch can be adjusted when necessary. CAUTION: The switch can only be adjusted during initial installation. If the switch is not adjusted properly, a new switch must be installed. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Description and Operation > General Information > Page 881 Brake Light Switch: Description and Operation Switch With RWAL System SYSTEM OPERATION Vehicles equipped with the speed control option use a dual function stop lamp switch. The switch is mounted on the brake pedal mounting bracket under the instrument panel. The PCM monitors the state of the dual function stop lamp switch. BRAKE SWITCH-PCM INPUT When the brake light switch is activated, the Powertrain Control Module (PCM) receives an input indicating that the brakes are being applied. After receiving this input, the PCM maintains idle speed to a scheduled rpm through control of the Idle Air Control (IAC) motor. The brake switch input is also used to supply/deny power to the speed control servo solenoids. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Description and Operation > Page 882 Brake Light Switch: Testing and Inspection The content of this article reflects changes called for in TSB 26-12-98. Stop Lamp Switch Terminal Identification The stop lamp switch can be tested with an ohmmeter. The ohmmeter is used to check continuity between the pin terminals. SWITCH CIRCUIT IDENTIFICATION - Terminals 1 and 2: stop lamp circuit - Terminals 3 and 4: RWAL/ABS module and Powertrain Control Module (PCM) circuit - Terminals 5 and 6: speed control circuit. NOTE: Disconnect switch harness before testing switch continuity. SWITCH CONTINUITY TEST With switch plunger extended, attach test leads to pins 1 and 2. Replace switch if meter indicates no continuity. With switch plunger retracted, attach test leads to pins 3 and 4. Replace switch if meter indicates no continuity. With switch plunger retracted, attach test leads to pins 5 and 6. Replace switch if meter indicates no continuity. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Description and Operation > Page 883 Brake Light Switch: Adjustments The content of this article reflects changes called for in TSB 26-12-98. To adjust a new switch after installation, release the brake pedal. Then move the release lever on the switch to engage the switch plunger. CAUTION: The switch can only be adjusted during initial installation. If the switch is not adjusted properly, a new switch must be installed. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Description and Operation > Page 884 Brake Light Switch: Service and Repair The content of this article reflects changes called for in TSB 26-12-98. REMOVAL 1. Remove knee bolster for access to stop lamp switch and pedal. Stop Lamp Switch & Harness Connector 2. Disconnect switch harness. 3. Press and hold brake pedal in applied position. 4. Rotate switch counterclockwise about 30° to align switch lock tab with notch in bracket. 5. Pull switch rearward out of mounting bracket and release brake pedal. INSTALLATION 1. Connect harness wires to new switch. 2. Press and hold brake pedal down. Stop Lamp Switch 3. Install switch. Align tabs on switch with notch in switch bracket. Then insert switch in bracket and turn it clockwise about 30° to lock it in place. 4. Release brake pedal. Then move the release lever on the switch to engage the switch plunger. The switch is now adjusted and cannot be adjusted again. 5. Install the knee bolster. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions Door Switch: Diagram Information and Instructions Introduction General Information (Part 1 Of 2) Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 889 General Information (Part 2 Of 2) Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Function Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 890 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 891 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 892 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 893 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 894 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 895 Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 896 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 897 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 898 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 899 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 900 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Terminal/Connector Repair-Thomas and Betts Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 901 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector. Removing Wire Terminal 4. Insert the probe end of Special Tool 6934 into the back of the connector cavity. 5. Grasp the wire and Special Tool 6934 and slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal. 7. Install the wire and terminal in the connector. Fully seat the terminal in the connector. Single Lock Tab 8. Push in the single lock tab on the side of the connector. Wiring Repair Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 902 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 903 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 904 Door Switch: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 905 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 906 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 907 Door Switch: Connector Views Driver Door Jamb Switch (CTM) - Natural 2 Way Passenger Door Jamb Switch - Natural 3 Way Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Glove Box Lamp Switch > Component Information > Locations Glove Box Lamp And Switch Remove/Install Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Glove Box Lamp Switch > Component Information > Locations > Page 911 Glove Box Lamp Switch: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO RESTRAINT SYSTEMS / AIRBAG SYSTEMS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY . Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Glove Box Lamp Switch > Component Information > Locations > Page 912 Glove Box Lamp Switch: Service and Repair Glove Box Lamp And Switch Remove/Install WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIR BAGS AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the glove box from the instrument panel. Refer to Glove Box in the Replacement for the procedures. 3. Reach through the glove box opening and behind the glove box lamp and switch mounting bracket to access the instrument panel wire harness connector on the glove box lamp and switch. 4. Disconnect the instrument panel wire harness connector from the connector receptacle on the back of the glove box lamp and switch unit. 5. Reach through the glove box opening and behind the glove box lamp and switch mounting bracket to depress the retaining tabs on the top and bottom of the glove box lamp and switch housing. 6. While holding the retaining tabs depressed, push the glove box lamp and switch unit out through the hole in the mounting bracket on the instrument panel glove box opening upper reinforcement. 7. Remove the glove box lamp and switch unit from the instrument panel. INSTALLATION 1. Reach through the glove box opening and behind the glove box lamp and switch mounting bracket to feed the instrument panel wire harness connectors out through the hole in the glove box lamp and switch housing mounting bracket. 2. Position the glove box lamp and switch unit to the instrument panel. 3. Reconnect the instrument panel wire harness connector to the connector receptacle on the back of the glove box lamp and switch unit. 4. Push the glove box lamp and switch unit into the hole in the mounting bracket on the instrument panel glove box opening upper reinforcement. 5. Install the glove box onto the instrument panel. Refer to Glove Box in the Replacement for the procedures. 6. Close the glove box. 7. Reconnect the battery negative cable. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Specifications Hazard Warning Switch: Specifications Tighten the screw that secures the instrument panel wire harness connector to the multi-function switch connector receptacle to 2 Nm (17 in lbs). Tighten the two screws that secure the multi-function switch to the steering column to 2 Nm (17 in lbs). Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Specifications > Page 916 Hazard Warning Switch: Locations Multi-Function Switch The turn signal and hazard warning switches are integral to the multi-function switch unit, which is secured to the left side of the steering column. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Specifications > Page 917 Multi-Function Switch - 24 Way Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Specifications > Page 918 Hazard Warning Switch: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO RESTRAINT SYSTEMS / AIRBAG SYSTEMS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY . Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Specifications > Page 919 Hazard Warning Switch: Description and Operation DESCRIPTION Multi-Function Switch The turn signal and hazard warning switches are integral to the multi-function switch unit, which is secured to the left side of the steering column. The only visible parts of the multi-function switch are the control stalk that extends from the left side of the steering column, and the hazard warning switch push button that protrudes from the top of the steering column. The multi-function switch control stalk has both nomenclature and international control symbols on it, which identify its many functions. The hazard warning switch push button is identified with a double triangle, which is the international control symbol for hazard warning. The remainder of the mufti-function switch is concealed beneath the steering column shrouds. The multi-function switch also contains circuitry for the following functions: Headlamp beam selection - Headlamp optical horn - Windshield wipers - Windshield washers. However, the turn signal and hazard warning switches cannot be repaired. If these switches or any other circuit or component of the multi-function switch unit is faulty or damaged, the entire multifunction switch unit must be replaced. OPERATION The hazard warning switch is controlled by the hazard warning switch push button. Push the switch button in to unlatch the switch and activate the hazard warning system, and push in on the button again to latch the switch and turn the system off. When the hazard warning switch is latched (hazard warning off), the push button will be in a lowered position on the top of the steering column shroud; and, when the hazard warning switch is unlatched (hazard warning on), the push button will be in a raised position. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Specifications > Page 920 Hazard Warning Switch: Testing and Inspection The turn signal switch and the hazard warning switch are integral to the multi-function switch. Refer to Turn Signal and Hazard Warning Systems in the Diagnosis and Testing before testing the multi-function switch. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIR BAGS AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. Disconnect the instrument panel wire harness connector from the multi-function switch connector receptacle. Multi-Function Switch Continuity 2. Using an ohmmeter, perform the switch continuity checks at the connector receptacle terminals as shown in the Multi-Function Switch Continuity chart. 3. If the turn signal switch or hazard warning switch fails any of the continuity checks, replace the faulty multi-function switch assembly as required. If the switch circuits are OK, repair the lighting circuits as required. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Specifications > Page 921 Hazard Warning Switch: Service and Repair WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIR BAGS AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. If the vehicle is so equipped, remove the tilt lever from the left side of the steering column. Steering Column Shrouds Remove/Install 3. Remove both the upper and lower shrouds from the steering column. 4. Remove the lower fixed column shroud from the steering column. Multi-Function Switch Connector - Typical 5. Move the upper fixed column shroud far enough to access the back of the multi-function switch. 6. Remove the tamper proof mounting screws (a Snap On tamper proof Torx bit TTXR20B2 or equivalent is required) that secure the multi-function switch to the steering column. 7. Gently pull the multi-function switch away from the steering column far enough to access and remove the screw that secures the instrument panel wire harness connector to the multi-function switch connector receptacle. 8. Disconnect the instrument panel wire harness connector from the multi-function switch connector receptacle. 9. Remove the multi-function switch from the steering column. INSTALLATION 1. Position the multi-function switch onto the steering column. 2. Reconnect the instrument panel wire harness connector to the multi-function switch connector receptacle. 3. Install and tighten the screw that secures the instrument panel wire harness connector to the multi-function switch connector receptacle. Tighten Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Specifications > Page 922 the screw to 2 Nm (17 in lbs). 4. Install and tighten the two screws that secure the multi-function switch to the steering column. Tighten the screws to 2 Nm (17 in lbs). 5. Install the lower fixed column shroud onto the steering column. 6. Install both the upper and lower shrouds onto the steering column. 7. If the vehicle is so equipped install the tilt lever onto the left side of the steering column. 8. Reconnect the battery negative cable. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Specifications Headlamp Switch: Specifications Tighten the three screws that secure the headlamp switch to the instrument panel to 2.2 Nm (20 in lbs). Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Specifications > Page 926 Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Specifications > Page 927 Headlamp Switch: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO RESTRAINT SYSTEMS / AIRBAG SYSTEMS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY . Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Specifications > Page 928 Headlamp Switch: Application and ID CAUTION: Do not use bulbs that have a higher candle power than the bulb listed. Damage to lamp can result. Some components have lamps that can only be serviced by a Authorized Service Center (ASC) after the component is removed from the vehicle. When illumination goes out in the Electronic Instrument Cluster (EIC) the complete button module must be replaced. The Mechanical Instrument Cluster (MIC) uses PC 194 bulbs for illumination. When changing lamp bulbs check the socket for corrosion. If corrosion is present, clean it with a wire brush and coat the inside of the socket lightly with Mopar Multi-Purpose Grease or equivalent. Headlamp Switch = Bulb Number 158 Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Specifications > Page 929 Headlamp Switch: Service and Repair Headlamp Switch Remove/Install WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIR BAGS AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the cluster bezel from the instrument panel. Refer to Cluster Bezel in the Replacement for the procedures. 3. Remove the three screws that secure the headlamp switch bezel to the instrument panel. 4. Pull the headlamp switch away from the instrument panel far enough to access the instrument panel wire harness connectors. 5. Disconnect the two instrument panel wire harness connectors from the headlamp switch connector receptacles. 6. Remove the headlamp switch from the instrument panel. INSTALLATION 1. Position the headlamp switch to the instrument panel. 2. Reconnect the two instrument panel wire harness connectors to the headlamp switch connector receptacles. 3. Install the headlamp switch into the instrument panel. 4. Install and tighten the three screws that secure the headlamp switch to the instrument panel. Tighten the screws to 2.2 Nm (20 in lbs). 5. Install the cluster bezel onto the instrument panel. Refer to Cluster Bezel in the Replacement for the procedures. 6. Reconnect the battery negative cable. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Diagrams > Diagram Information and Instructions Horn Switch: Diagram Information and Instructions Introduction General Information (Part 1 Of 2) Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 934 General Information (Part 2 Of 2) Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Function Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 935 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 936 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 937 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 938 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 939 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 940 Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 941 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 942 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 943 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 944 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 945 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Terminal/Connector Repair-Thomas and Betts Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 946 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector. Removing Wire Terminal 4. Insert the probe end of Special Tool 6934 into the back of the connector cavity. 5. Grasp the wire and Special Tool 6934 and slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal. 7. Install the wire and terminal in the connector. Fully seat the terminal in the connector. Single Lock Tab 8. Push in the single lock tab on the side of the connector. Wiring Repair Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 947 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 948 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 949 Horn Switch: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 950 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 951 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Diagrams > Page 952 Horn Switch: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIR BAGS AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY . Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Diagrams > Page 953 Horn Switch: Description and Operation Driver Side Airbag Module Trim Cover And Horn Switch DESCRIPTION A center-blow, normally open, resistive membrane-type horn switch is secured with heat stakes to the back side of the driver side airbag module trim cover in the center of the steering wheel. The switch consists of two plastic membranes, one that is flat and one that is slightly convex. These two membranes are secured to each other around the perimeter. Inside the switch, the centers of the facing surfaces of these membranes each has a grid made with an electrically conductive material applied to it. One of the grids is connected to a circuit that provides it with continuity to ground at all times. The grid of the other membrane is connected to the horn relay control circuit. The steering wheel and steering column must be properly grounded in order for the horn switch to function properly. The horn switch is only serviced as a part of the driver side airbag module trim cover. If the horn switch is damaged or faulty, or if the driver side airbag is deployed, the driver side airbag module trim cover and horn switch must be replaced as a unit. OPERATION When the center area of the driver side airbag trim cover is depressed, the electrically conductive grids on the facing surfaces of the horn switch membranes A contact each other, closing the switch circuit. The completed horn switch circuit provides a ground for the control coil side of the horn relay, which activates the relay. When the horn switch is released, the resistive tension of the convex membrane separates the two electrically conductive grids and opens the switch circuit. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Diagrams > Page 954 Horn Switch: Testing and Inspection WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIR BAGS AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. For additional testing and inspection information please refer to Powertrain Management/Computers and Control Systems/ See: Body and Frame/Body Control Systems/Central Timer Module 1. Disconnect and isolate the battery negative cable. Remove the steering column opening cover from the instrument panel. 2. Check for continuity between the metal steering column jacket and a good ground. There should be continuity. If OK, go to Step 3. 3. Remove the driver side airbag module from the steering wheel. Disconnect the horn switch wire harness connectors from the driver side airbag module. 4. Remove the horn relay from the Power Distribution Center (PDC). Check for continuity between the steering column half of the horn switch feed wire harness connector and a good ground. There should be no continuity. If OK, go to Step 5. If not OK repair the shorted horn relay control circuit to the horn relay in the PDC as required. 5. Check for continuity between the steering column half of the horn switch feed wire harness connector and the horn relay control circuit cavity for the horn relay in the PDC. There should be continuity If OK, go to Step 6. If not OK, repair the open horn relay control circuit to the horn relay in the PDC as required. 6. Check for continuity between the horn switch feed wire and the horn switch ground wire on the driver side airbag module. There should be no continuity. If OK, go to Step 7. If not OK, replace the faulty horn switch. 7. Depress the center of the driver side airbag module trim cover and check for continuity between the horn switch feed wire and the horn switch ground wire on the driver side airbag module. There should now be continuity. If not OK, replace the faulty horn switch. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Interior Light Switch > Component Information > Diagrams > Diagram Information and Instructions Interior Light Switch: Diagram Information and Instructions Introduction General Information (Part 1 Of 2) Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Interior Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 959 General Information (Part 2 Of 2) Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Function Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Interior Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 960 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Interior Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 961 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Interior Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 962 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Interior Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 963 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Interior Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 964 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Interior Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 965 Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Interior Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 966 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Interior Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 967 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Interior Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 968 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Interior Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 969 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Interior Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 970 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Terminal/Connector Repair-Thomas and Betts Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Interior Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 971 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector. Removing Wire Terminal 4. Insert the probe end of Special Tool 6934 into the back of the connector cavity. 5. Grasp the wire and Special Tool 6934 and slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal. 7. Install the wire and terminal in the connector. Fully seat the terminal in the connector. Single Lock Tab 8. Push in the single lock tab on the side of the connector. Wiring Repair Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Interior Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 972 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Interior Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 973 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Interior Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 974 Interior Light Switch: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Interior Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 975 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Interior Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 976 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Specifications Turn Signal Switch: Specifications Tighten the screw that secures the instrument panel wire harness connector to the multi-function switch connector receptacle to 2 Nm (17 in lbs). Tighten the two screws that secure the multi-function switch to the steering column to 2 Nm (17 in lbs). Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Specifications > Page 980 Turn Signal Switch: Locations Multi-Function Switch The turn signal and hazard warning switches are integral to the multi-function switch unit, which is secured to the left side of the steering column. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Specifications > Page 981 Multi-Function Switch - 24 Way Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Specifications > Page 982 Turn Signal Switch: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO RESTRAINT SYSTEMS / AIRBAG SYSTEMS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY . Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Specifications > Page 983 Turn Signal Switch: Description and Operation Multi-Function Switch DESCRIPTION The turn signal and hazard warning switches are integral to the multi-function switch unit, which is secured to the left side of the steering column. The only visible parts of the multi-function switch are the control stalk that extends from the left side of the steering column, and the hazard warning switch push button that protrudes from the top of the steering column. The multi-function switch control stalk has both nomenclature and international control symbols on it, which identify its many functions. The hazard warning switch push button is identified with a double triangle, which is the international control symbol for hazard warning. The remainder of the mufti-function switch is concealed beneath the steering column shrouds. The multi-function switch also contains circuitry for the following functions: Headlamp beam selection - Headlamp optical horn - Windshield wipers - Windshield washers. However, the turn signal and hazard warning switches cannot be repaired. If these switches or any other circuit or component of the multi-function switch unit is faulty or damaged, the entire multifunction switch unit must be replaced. OPERATION The multi-function switch control stalk that extends from the left side of the steering column just below the steering wheel is moved up or down to activate the turn signal switch. When the control stalk is moved in the upward direction, the right turn signal switch circuitry is activated; and, when the control stalk is moved in the downward direction, the left turn signal switch circuitry is activated. The turn signal switch has a detent position in each direction that provides turn signals with automatic cancellation, and an intermediate momentary position in each direction that provides turn signals only until the multi-function switch control stalk is released. When the turn signal switch is in a detent position, it is turned off by one of two turn signal cancelling cam lobes that are integral to the rotor of the clockspring mechanism. Turning the steering wheel causes the turn signal cancelling cam lobes to contact a cancel actuator in the multi-function switch, and the turn signal switch automatically returns to the off position. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Specifications > Page 984 Turn Signal Switch: Testing and Inspection Multi-Function Switch Continuity The turn signal switch and the hazard warning switch are integral to the multi-function switch. Refer to Turn Signal and Hazard Warning Systems in the Diagnosis and Testing before testing the multi-function switch. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIR BAGS AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. Disconnect the instrument panel wire harness connector from the multi-function switch connector receptacle. 2. Using an ohmmeter, perform the switch continuity checks at the connector receptacle terminals as shown in the Multi-Function Switch Continuity chart. 3. If the turn signal switch or hazard warning switch fails any of the continuity checks, replace the faulty multi-function switch assembly as required. If the switch circuits are OK, repair the lighting circuits as required. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Specifications > Page 985 Turn Signal Switch: Service and Repair WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIR BAGS AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. If the vehicle is so equipped, remove the tilt lever from the left side of the steering column. Steering Column Shrouds Remove/Install 3. Remove both the upper and lower shrouds from the steering column. 4. Remove the lower fixed column shroud from the steering column. Multi-Function Switch Connector - Typical 5. Move the upper fixed column shroud far enough to access the back of the multi-function switch. 6. Remove the tamper proof mounting screws (a Snap On tamper proof Torx bit TTXR20B2 or equivalent is required) that secure the multi-function switch to the steering column. 7. Gently pull the multi-function switch away from the steering column far enough to access and remove the screw that secures the instrument panel wire harness connector to the multi-function switch connector receptacle. 8. Disconnect the instrument panel wire harness connector from the multi-function switch connector receptacle. 9. Remove the multi-function switch from the steering column. INSTALLATION 1. Position the multi-function switch onto the steering column. 2. Reconnect the instrument panel wire harness connector to the multi-function switch connector receptacle. 3. Install and tighten the screw that secures the instrument panel wire harness connector to the multi-function switch connector receptacle. Tighten Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Specifications > Page 986 the screw to 2 Nm (17 in lbs). 4. Install and tighten the two screws that secure the multi-function switch to the steering column. Tighten the screws to 2 Nm (17 in lbs). 5. Install the lower fixed column shroud onto the steering column. 6. Install both the upper and lower shrouds onto the steering column. 7. If the vehicle is so equipped install the tilt lever onto the left side of the steering column. 8. Reconnect the battery negative cable. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Specifications Accelerator Pedal Position Sensor: Specifications Accelerator Pedal Position Sensor Bracket Bolts 12 Nm Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Specifications > Page 992 APPS Assembly, Lever, Mounting Bolts(6), Wire Harness Clip, Calibration Screws (No Adjustment) Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Specifications > Page 993 Accelerator Pedal Position Sensor: Description and Operation ACCELERATOR PEDAL POSITION SENSOR (APPS)-ECM INPUT The Accelerator Pedal Position Sensor (APPS) is a linear potentiometer. It provides the Engine Control Module (ECM) with a DC voltage signal proportional to the angle, or position of the accelerator pedal. In previous model years, this part was known as the Throttle Position Sensor (TPS). Diesel engines used in previous model years used a mechanical cable between the accelerator pedal and the TPS lever. Linkage and bellcranks between the TPS cable lever and the fuel injection pump were also used. Although the cable has been retained with the APPS, the linkage and bellcranks between the cable lever and the fuel injection pump are no longer used. APPS Assembly Location APPS Sensor Location (Rear View) The APPS assembly is located at the top-left-front of the engine. A plastic cover is used to cover the assembly. The actual sensor is located behind its mounting bracket. The APPS is serviced (replaced) as one assembly including the lever, brackets and sensor. The APPS is calibrated and permanently positioned to its mounting bracket. CAUTION: Do not attempt to remove sensor from its mounting bracket as electronic calibration will be destroyed (sensor-to-bracket mounting screws are permanently attached). Two accelerator lever set screws are used to position lever. Do not attempt to alter positions of these set screws as electronic calibration will be destroyed. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Specifications > Page 994 Accelerator Pedal Position Sensor: Service and Repair Cable/Lever/Linkage/Cover The APPS is serviced (replaced) as one assembly including the lever, brackets and sensor. The APPS is calibrated to its mounting bracket. The APPS assembly is located at left-front of engine below plastic cable/lever/linkage cover. APPS Assembly CAUTION: Do not attempt to remove sensor from its mounting bracket as electronic calibration will be destroyed (sensor-to-bracket mounting screws are permanently attached). Two accelerator lever set screws are used to position lever. Do not attempt to alter positions of these set screws as electronic calibration will be destroyed. REMOVAL 1. Disconnect both negative battery cables at both batteries. 2. Remove cable cover. Cable cover is attached with 2 Phillips screws, 2 plastic retention clips and 2 push tabs. Remove 2 Phillips screws and carefully pry out 2 retention clips. After clip removal, push rearward on front tab, and upward on lower tab for cover removal. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Specifications > Page 995 Cables At Throttle Lever 3. Using finger pressure only, disconnect end of speed control servo cable from throttle lever pin by pulling forward on connector while holding lever rearward.DO NOT try to pull connector off perpendicular to lever pin. Connector will be broken. 4. Using two small screwdrivers, pry throttle cable connector socket from throttle lever ball. Be very careful not to bend throttle lever arm. 5. Disconnect transmission control cable at lever arm (if equipped). 6. Squeeze pinch tabs on speed control cable and pull cable rearward to remove from cable mounting bracket. 7. Squeeze pinch tabs on throttle cable and pull cable rearward to remove from cable mounting bracket. 8. If equipped with an automatic transmission, refer to Transmission for transmission control cable removal procedures. 9. Disconnect wiring harness clip at bottom of bracket. Electrical Connector At Bottom Of APPS 10. Remove 6 mounting bolts and partially remove APPS assembly from engine. After assembly is partially removed, disconnect electrical connector from bottom of sensor by pushing on connector tab. 11. Remove APPS assembly from engine. INSTALLATION 1. Snap electrical connector into bottom of sensor. 2. Position APPS assembly to engine and install 6 bolts. Tighten bolts to 12 Nm (105 in. lbs.) torque. 3. Connect wiring harness clip at bottom of bracket. 4. If equipped with an automatic transmission, refer to Transmission for transmission control cable installation procedures. 5. Install speed control cable into mounting bracket. Be sure pinch tabs have secured cable. 6. Install throttle cable into mounting bracket. Be sure pinch tabs have secured cable. 7. Connect throttle cable at lever (snaps on). 8. Connect speed control cable to lever by pushing cable connector rearward onto lever pin while holding lever forward. 9. Install cable cover. 10. Connect both negative battery cables to both batteries. 11. ECM Calibration: Turn key to ON position. Without starting engine, slowly press throttle pedal to floor and then slowly release. This step must be Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Specifications > Page 996 done (one time) to ensure accelerator pedal position sensor calibration has been learned by ECM. If not done, possible DTC's may be set. 12. Use DRB scan tool to erase any DTC's from ECM/PCM. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations Battery Temperature Sensor: Locations Battery Temperature Sensor Location The sensor is located under the battery and is attached (snapped into) the battery tray. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 1000 Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 1001 Battery Temperature Sensor: Service Precautions WARNING: TO PROTECT THE HANDS FROM BATTERY ACID, A SUITABLE PAIR OF HEAVY DUTY RUBBER GLOVES, NOT THE HOUSEHOLD TYPE, SHOULD BE WORN WHEN REMOVING OR SERVICING A BATTERY. SAFETY GLASSES ALSO SHOULD BE WORN . Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 1002 Battery Temperature Sensor: Description and Operation SYSTEM OPERATION The battery temperature sensor is used to determine the battery temperature and control battery charging rate. This temperature data, along with data from monitored line voltage, is used by the PCM to vary the battery charging rate. System voltage will be higher at colder temperatures and is gradually reduced at warmer temperatures. BATTERY TEMPERATURE SENSOR-PCM INPUT Provides a signal to the PCM corresponding to the battery temperature. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Testing and Inspection > Testing Battery Temperature Sensor: Testing and Inspection Testing To perform a complete test of this sensor and its circuitry, refer to the appropriate Powertrain Diagnostic Procedures. To test the sensor only, refer to the following: Battery Temperature Sensor Location 1. The sensor is located on the driver's side of the vehicle under the battery and is attached to (snapped into) the battery tray. Only one sensor is used, including vehicles with dual batteries (diesel engines). A two-wire pigtail harness is attached directly to the sensor. The opposite end of this harness connects the sensor to the engine wiring harness. 2. Disconnect the two-wire pigtail harness from the engine harness. 3. Attach ohmmeter leads to the wire terminals of the pigtail harness. 4. At room temperature of 25° C (75-80° F), an ohmmeter reading of 9,000 (9K) to 11,000 (11K) ohms should be observed. 5. If reading is above or below the specification, replace the sensor. 6. Refer to the Replacement for procedures. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Testing and Inspection > Page 1005 Battery Temperature Sensor: Service and Repair Battery Temperature Sensor Location The battery temperature sensor is located under the vehicle battery and is attached (snapped into) a mounting hole on battery tray. Only one sensor is used (dual batteries). The sensor is located under the battery on drivers side of vehicle. REMOVAL 1. Remove battery. Refer to Battery for procedures 2. Disconnect sensor pigtail harness from engine wire harness. 3. Pry sensor straight up from battery tray mounting hole. INSTALLATION 1. Feed pigtail harness through mounting hole in top of battery tray and press sensor into top of tray (snaps in). 2. Connect pigtail harness. 3. Install battery. Refer to Battery for procedures. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications Camshaft Position Sensor: Specifications Camshaft Position Sensor (CMP) Bolt 20 Nm Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 1009 Camshaft Position Sensor: Locations Camshaft Position Sensor (CMP) Location The camshaft position sensor (CMP) is located below the fuel injection pump. It is attached to the back of the timing gear cover housing. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 1010 Connector View Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 1011 Camshaft Position Sensor: Description and Operation CAMSHAFT POSITION SENSOR (CMP)-ECM INPUT Camshaft Position Sensor (CMP) The Camshaft Position Sensor (CMP) contains a hall effect device called a sync signal generator to generate a sync signal. The sync signal generator detects a machined hole on the rear face of the camshaft drive gear. The signal is used to verify the position of the #1 cylinder during engine operation. When the leading edge of the machined hole enters the tip of the CMP the interruption of magnetic field causes the voltage to switch high resulting in a signal of approximately 5 volts. When the trailing edge of the machined hole leaves the tip of the CMP the change of the magnetic field causes the voltage to switch low to 0 volts. Camshaft Position Sensor (CMP) Location The CMP is located below the fuel injection pump. It is attached to the back of the timing gear cover housing. The CMP is not used for any control of fuel system. It is used only for diagnostic purposes. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 1012 Camshaft Position Sensor: Service and Repair Camshaft Position Sensor (CMP) Location The camshaft position sensor (CMP) is located below the fuel injection pump. It is attached to the back of the timing gear cover housing. REMOVAL 1. Disconnect both negative cables from both batteries. 2. Clean area around CMP. 3. Disconnect electrical at CMP. Camshaft Position Sensor (CMP) Removal/Installation 4. Remove CMP mounting bolt. Bolt head is female-hex. 5. Remove CMP from engine by twisting and pulling straight back. 6. Discard CMP O-ring. INSTALLATION 1. Install new O-ring to CMP. Apply clean engine oil to O-ring. 2. Clean area around CMP mounting hole. 3. To prevent tearing O-ring, install CMP into gear housing using a twisting action. 4. Install mounting bolt and tighten to 20 Nm (15 ft. lbs.) torque. 5. Install electrical connector to CMP. 6. Connect both negative cables to both batteries. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications Coolant Temperature Sensor/Switch (For Computer): Specifications Engine Coolant Temperature(ECT) Sensor 14 Nm Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 1016 Coolant Temperature Sensor/Switch (For Computer): Locations Engine Coolant Temperature Sensor The engine coolant temperature sensor is installed into the front of the cylinder head near to the thermostat housing and protrudes into a water jacket. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 1017 Connector View Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 1018 Coolant Temperature Sensor/Switch (For Computer): Description and Operation ENGINE COOLANT TEMPERATURE (ECT) SENSOR-ECM INPUT Engine Coolant Temperature Sensor The engine coolant temperature sensor is installed into the front of the cylinder head near to the thermostat housing and protrudes into a water jacket. The sensor provides an input voltage to the Engine Control Module (ECM) to monitor coolant temperature. The ECM uses this input along with inputs from other sensors for engine protection, fuel timing and fuel control. As coolant temperature varies, the coolant temperature sensor resistance will change. This change in resistance results in a different input voltage to the ECM. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 1019 Coolant Temperature Sensor/Switch (For Computer): Service and Repair ECT Sensor Location The Engine Coolant Temperature (ECT) sensor is located at the front of the cylinder head near the thermostat. REMOVAL WARNING: THE COOLING SYSTEM MAY BE UNDER PRESSURE. HOT COOLANT CAN CAUSE BURNS. 1. Partially drain cooling system until coolant level is below cylinder head. 2. Disconnect ECT sensor electrical connector from sensor. ECT Sensor Removal/Installation 3. Remove ECT sensor from cylinder head. 4. Discard sensor O-ring. INSTALLATION 1. Clean sensor mounting hole of rust or contaminants. 2. Install new O-ring to sensor. Apply clean engine oil to sensor O-ring and sensor threads. 3. Install ECT sensor into cylinder head. Tighten to 14 Nm (10 ft. lbs.) torque. 4. Connect sensor electrical connector. 5. fill cooling system and check for coolant leaks. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Engine Speed Sensor > Component Information > Specifications Engine Speed Sensor: Specifications Sensor To Vibration Damper Air Gap Minimum .............................................................................................................................................. ................................................ 1.25 mm (.049 in) Maximum ............................................................... .............................................................................................................................. 1.30 mm (.051 in) Torque Engine Speed Sensor Nuts/Bolts ......................................................................................................................................................... 24 N.m (18 ft. lbs.) Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Engine Speed Sensor > Component Information > Specifications > Page 1023 Engine Speed Sensor: Locations Crankshaft Position Sensor (CKP) Location The CKP sensor is located on the left rear side of engine block near the starter motor. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Engine Speed Sensor > Component Information > Specifications > Page 1024 Connector View Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Engine Speed Sensor > Component Information > Specifications > Page 1025 Engine Speed Sensor: Description and Operation CRANKSHAFT POSITION SENSOR (CKP)-ECM INPUT Crankshaft Position Sensor (CKP) Location The Crankshaft Position Sensor (CKP) is located on the lower left-rear side of the engine behind the starter motor. Engine speed and crankshaft position are provided through the CKP. The sensor generates pulses that are the input sent to the Engine Control Module (ECM). The ECM interprets the sensor input to determine the crankshaft position. The ECM then uses this position, along with other inputs, to determine injector firing sequence and fuel timing. The sensor must be powered up by 5 volts to operate. The sensor is a hall effect device combined with an internal magnet. It is also sensitive to steel within a certain distance from it. Crankshaft Tone Wheel The engine crankshaft is equipped with a bolt-on tone wheel. The tone wheel is equipped with 35 teeth and a gap where the 36th tooth should be placed. This missing tooth indicates to the ECM the relative position of cylinder #1 to the Top Dead Center (TDC) position. This does not mean that cylinder #1 is at TDC. When the CKP is aligned with the missing tooth, the missing tooth is 60 degrees away from cylinder #1 TDC position. The teeth cause pulses to be generated when they pass under the sensor. The pulses are the input to the ECM. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Engine Speed Sensor > Component Information > Specifications > Page 1026 Engine Speed Sensor: Testing and Inspection The perform a complete test of this sensor and its circuitry. Refer to the DRB scan tool. Also refer to the appropriate powertrain Diagnostics Procedures. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Engine Speed Sensor > Component Information > Specifications > Page 1027 Engine Speed Sensor: Service and Repair REMOVAL Crankshaft Position Sensor (CKP) Location The CKP is located on the left/rear side of engine block near the starter motor. 1. Disconnect both negative battery cables at both batteries. 2. Remove starter motor. Refer to Starter. 3. Disconnect electrical connector at CKP. 4. Remove CKP mounting bolt and hold down bracket. 5. Pull CKP from engine block with a slight twisting action. CKP Removal/Installation 6. Discard old CKP O-ring. INSTALLATION 1. Install new O-ring to CKP Apply clean engine oil to O-ring. 2. Clean area around CKP mounting hole. 3. To prevent tearing O-ring, install CKP into engine block using a twisting action. 4. Position hold down bracket and install mounting bolt. 5. tighten bolt to 24 Nm (18 ft. lbs.) torque. 6. Install starter motor. Refer to Starter. 7. Connect both negative battery cables at both batteries. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications Intake Air Temperature Sensor: Specifications Intake Manifold Air Temperature(IAT) Sensor 14 Nm Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications > Page 1031 Intake Air Temperature Sensor: Locations Intake Manifold Air Temperature (IAT) Sensor Location The intake manifold air temperature sensor is installed into the rear of the intake manifold. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications > Page 1032 Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications > Page 1033 Intake Air Temperature Sensor: Description and Operation INTAKE MANIFOLD AIR TEMPERATURE (IAT) SENSOR-ECM INPUT The IAT provides an input voltage to the Engine Control Module (ECM) indicating intake manifold air temperature. The input is used along with inputs from other sensors for engine protection, fuel timing and fuel control. As the temperature of the air-fuel stream in the manifold varies, the sensor resistance changes. This results in a different input voltage to the ECM. Intake Manifold Air Temperature (IAT) Sensor Location The intake manifold air temperature sensor is installed into the rear of the intake manifold with the sensor element extending into the air stream. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications > Page 1034 Intake Air Temperature Sensor: Service and Repair IAT Sensor Location The IAT sensor is located in the left/rear side of the intake manifold. REMOVAL 1. Disconnect electrical connector from IAT sensor. IAT Sensor Removal/Installation 2. Remove IAT sensor from intake manifold. 3. Discard sensor O-ring. INSTALLATION 1. Clean sensor mounting hole of rust or contaminants. 2. Install new O-ring to sensor. Apply clean engine oil to sensor O-ring and sensor threads. 3. Install IAT sensor into intake manifold. tighten to 14 Nm (10 ft. lbs.) torque. 4. Connect sensor electrical connector. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications Manifold Pressure/Vacuum Sensor: Specifications Manifold Air Pressure Sensor 14 Nm Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 1038 Manifold Pressure/Vacuum Sensor: Locations MAP Sensor Location The MAP sensor is installed into the rear of the intake manifold. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 1039 Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 1040 Manifold Pressure/Vacuum Sensor: Description and Operation The MAP sensor reacts to air pressure changes in the intake manifold. It provides an input voltage to the Engine Control Module (ECM). As pressure changes, MAP sensor voltage will change. The change in MAP sensor voltage results in a different input voltage to the ECM. The ECM uses this input, along with inputs from other sensors to provide fuel timing, fuel control and engine protection. Engine protection is used to derate (drop power off) the engine if turbocharger pressure becomes to high. Intake Manifold Air Temperature (IAT) Sensor Location The MAP sensor is installed into the rear of the intake manifold. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 1041 Manifold Pressure/Vacuum Sensor: Service and Repair MAP Sensor Location The MAP sensor is located in the left/rear side of the intake manifold. REMOVAL 1. Disconnect electrical connector from MAP sensor. MAP Sensor Removal/Installation 2. Remove MAP sensor from intake manifold. 3. Discard sensor O-ring. INSTALLATION 1. Clean sensor mounting hole of rust or contaminants. 2. Install new O-ring to sensor. Apply clean engine oil to sensor O-ring and sensor threads. 3. Install MAP sensor into intake manifold. Tighten to 14 Nm (10 ft. lbs.) torque. 4. Connect sensor electrical connector. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Specifications Oil Pressure Sensor: Specifications Oil Pressure Sender/Switch 12 ft.lb Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Specifications > Page 1045 Oil Pressure Sensor: Locations Oil Pressure Sensor (Engine) Location The oil pressure sensor is installed into the oil pressure galley on the engine block. It is located below and to the rear of the ECM. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Specifications > Page 1046 Oil Pressure Sensor: Diagrams Engine Oil Pressure Sensor - 3 Way Engine Oil Pressure Sensor (Diesel) - 3 Way Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Specifications > Page 1047 Oil Pressure Sensor: Description and Operation A signal is sent from the engine oil pressure sensor (sending unit) to the Engine Control Module (ECM) relating to engine oil pressure. The ECM monitors this signal and converts it to a pressure value. This value is used by the ECM for the engine protection system. The pressure signal from the ECM is bussed to the instrument panel oil gauge/lamp via the CCD circuits. Oil Pressure Sensor (Engine) Location The oil pressure sensor is installed into the oil pressure galley on the engine block. It is located below and to the rear of the ECM. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Specifications > Page 1048 Oil Pressure Sensor: Service and Repair REMOVAL 1. Disconnect the battery negative cables. Oil Pressure Sensor Location 2. Disconnect the oil pressure sensor connector. 3. Using a suitable socket, remove the oil pressure sensor from the block (counter-clockwise). INSTALLATION Oil Pressure Sensor And O-Ring 1. If the sensor is not being replaced, inspect the O-ring and replace if necessary. 2. Install the oil pressure sensor and tighten to 16 Nm (144 inch lbs.) torque. 3. Connect the battery negative cables. 4. Start engine and check for oil leaks at the sensor. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Throttle Position Sensor: > 18-02-99 > Feb > 99 > Torque Converter Clutch - Erratic Operation Technical Service Bulletin # 18-02-99 Date: 990219 Torque Converter Clutch - Erratic Operation NUMBER: 18-02-99 GROUP: Vehicle Performance DATE: Feb. 19, 1999 SUBJECT: Erratic Torque Converter Clutch (TCC) Operation (5.9L Diesel Applications) OVERVIEW: This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software (calibration changes 98cal12 & 99cal14). MODELS: 1998 - 1999 (BR/BE) Ram Truck NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A 5.9L 24 VALVE DIESEL ENGINE AND AUTOMATIC TRANSMISSION BUILT BETWEEN JAN. 1, 1998 AND DEC. 18, 1998 (MDH 0101XX & 1218XX). SYMPTOM/CONDITION: Some vehicles may experience a surge like condition while in 4th gear. This may be caused by the Torque Converter Clutch (TCC) unlocking and locking when it should be consistently locked. The cause of this erratic operation has been identified as electrical noise from the Throttle Position Sensor (TPS) or Alternator. DIAGNOSIS: Using the Mopar Diagnostic System (MDS/MDS2) and or the Diagnostic Scan Tool (DRB III(R)) with the appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. Verify the condition by creating a custom display in the DRB III(R) and include the following: SENSORS (Output Shaft Speed, TPS Volts, Trans Temp Degree) & INPUTS/OUTPUTS (Brake Switch, Park/Neutral, ASD Relay Sense, Desired TC Clutch). Drive the vehicle with a helper monitoring the DRB III(R). Warm the engine and verify the transmission fluid temperature is greater than 32°F and consistent. Operate the vehicle with an output shaft speed greater than 2200 rpm. Verify that the brake switch shows a released status that is consistent and verify the park/neutral status reads D/R and is consistent. While keeping the output shaft speed above 2200 rpm, hold the throttle so the TPS reads 1 volt. Monitor the TC clutch status, it should be consistently locked. If the TC clutch status shows unlocking/locking, look to see if the TPS volts are fluctuating by 0.2 volts or more. It the conditions are met, perform the Repair Procedure. If a surge like condition is felt but the above test does not confirm the TCC unlocking/locking occurrence, further diagnosis and testing will be required. NOTE: WHENEVER A POWERTRAIN CONTROL MODULE (PCM) IS REPLACED DUE TO FAILURE, THE SOFTWARE OF THE REPLACEMENT CONTROLLER MUST BE VERIFIED FOR THE LATEST REVISION LEVEL. USE THE FLASH PROCEDURE TO UPDATE REPLACED CONTROLLERS AS NECESSARY. PARTS REQUIRED: 1 04669020 Label, Authorized Software Update 1 04275086 Label, Authorized Modification EQUIPMENT REQUIRED: 1 CH6000 Scan Tool (DRB III(R)) 1 CH7035 General Purpose Interface Bus Cable (GPIB) 1 CH7000/7001 J1962 Cable 1 MDS1 or MDS2 NOTE: THE MDS1/MDS2 AND DRB III(R) ARE REQUIRED TO PERFORM PART OF THIS REPAIR. IF USING THE MDS1 AND DRB III(R) THE MDS MUST BE OPERATING AT RELEASE 21 OR HIGHER AND TIL CD RELEASE 1179 OR HIGHER MUST BE INSTALLED. IF USING THE MDS2 AND DRB III(R) THE SYSTEM MUST BE OPERATING AT CIS CD2030 OR HIGHER. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Throttle Position Sensor: > 18-02-99 > Feb > 99 > Torque Converter Clutch - Erratic Operation > Page 1057 POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-42-95 0.5 Hrs. FAILURE CODE: FM - Flash Module MDS1 Procedure 1. Connect the MDS1 (Mopar Diagnostic System) and DRB III(R) (Scan Tool) to the vehicle and power them up. 2. Use the arrow keys and select # 2 CONNECT TO MDS1 OR MDS2 on the DRB III(R) MAIN MENU SCREEN. 3. Use the arrow keys and select MDS DIAGNOSTICS OR DRB III(R) UPDATE on the DRB III(R) MAIN MENU SCREEN. 4. Use the arrow keys and select DIAGNOSTIC MENU on the MDS1, then press NEXT MENU. 5. Use the arrow keys and select VEHICLE CONTROLLER PROGRAMMING on the MDS1, then press NEXT MENU. 6. Use the arrow keys and select PROGRAMMING OF ALL OTHER CONTROLLERS USING THE MDS1 & DRB III(R) on the MDS, then press NEXT MENU. 7. Follow the steps presented on the MDS1 and DRB III(R) that will allow the DRB III(R) to obtain the current part number of the PCM. 8. The MDS1 will display the vehicle's PCM part number and the replacement part number(s). Press NEXT MENU to begin programming. NOTE: A NO UPDATES AVAILABLE MESSAGE MAY BE DISPLAYED. CHECK THE PCM PART NUMBER ON THE VEHICLE AND COMPARE IT TO THE PART NUMBER DISPLAYED ON THE MDS. IF NO UPDATES ARE AVAILABLE, FIRST CHECK YOUR DIAGNOSTIC EQUIPMENT FOR THE LATEST SOFTWARE LEVELS AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION. 9. The MDS1 and DRB III(R) will prompt for any operator action needed during the remainder of the reprogramming process. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. 10. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Figure 1). Attach the label to the PCM and cover the label with the clear plastic overlay. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Throttle Position Sensor: > 18-02-99 > Feb > 99 > Torque Converter Clutch - Erratic Operation > Page 1058 11. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI label (Figure 2). MDS2 Procedures 1. Log onto the MDS2 system. 2. Connect the MDS2 (Mopar Diagnostic System) and DRB III(R) (Scan Tool) to the vehicle and switch the ignition key to "ON". 3. Use the arrow keys and select # 2 CONNECT TO MDS1 OR MDS2 on the DRB III(R) MAIN MENU SCREEN. 4. Use the arrow keys and select # 2 RUN MDS2 APPLICATION on the DRB III(R) MAIN MENU SCREEN. NOTE: ONCE MDS2, DRB III(R), AND VEHICLE COMMUNICATION HAS BEEN ESTABLISHED, THE CANNOT READ VIN FROM DRB III(R) MESSAGE (ON THE MDS2) WILL BE REPLACED BY THE VEHICLE VIN. PRESS THE "OK" BUTTON ON THE MDS2 TO REQUEST A MDS2 SESSION FOR THE VEHICLE VIN INDICATED. PRESS THE "OK" BUTTON WHEN ASKED TO BEGIN SESSION. 5. Push the FLASH tab on the MDS2. NOTE: A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION. 6. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. NOTE: A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION. 7. Select the new software part number with the light pen and click UPDATE CONTROLLER SOFTWARE. 8. The MDS2 and DRB III(R) will prompt for any operator action needed during the remainder of the reprogramming process. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. 9. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Figure 1). Attach the label to the PCM and cover the label with the clear plastic overlay. 10. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI label (Figure 2). Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Throttle Position Sensor: > 18-02-99 > Feb > 99 > Torque Converter Clutch Erratic Operation Technical Service Bulletin # 18-02-99 Date: 990219 Torque Converter Clutch - Erratic Operation NUMBER: 18-02-99 GROUP: Vehicle Performance DATE: Feb. 19, 1999 SUBJECT: Erratic Torque Converter Clutch (TCC) Operation (5.9L Diesel Applications) OVERVIEW: This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software (calibration changes 98cal12 & 99cal14). MODELS: 1998 - 1999 (BR/BE) Ram Truck NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A 5.9L 24 VALVE DIESEL ENGINE AND AUTOMATIC TRANSMISSION BUILT BETWEEN JAN. 1, 1998 AND DEC. 18, 1998 (MDH 0101XX & 1218XX). SYMPTOM/CONDITION: Some vehicles may experience a surge like condition while in 4th gear. This may be caused by the Torque Converter Clutch (TCC) unlocking and locking when it should be consistently locked. The cause of this erratic operation has been identified as electrical noise from the Throttle Position Sensor (TPS) or Alternator. DIAGNOSIS: Using the Mopar Diagnostic System (MDS/MDS2) and or the Diagnostic Scan Tool (DRB III(R)) with the appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. Verify the condition by creating a custom display in the DRB III(R) and include the following: SENSORS (Output Shaft Speed, TPS Volts, Trans Temp Degree) & INPUTS/OUTPUTS (Brake Switch, Park/Neutral, ASD Relay Sense, Desired TC Clutch). Drive the vehicle with a helper monitoring the DRB III(R). Warm the engine and verify the transmission fluid temperature is greater than 32°F and consistent. Operate the vehicle with an output shaft speed greater than 2200 rpm. Verify that the brake switch shows a released status that is consistent and verify the park/neutral status reads D/R and is consistent. While keeping the output shaft speed above 2200 rpm, hold the throttle so the TPS reads 1 volt. Monitor the TC clutch status, it should be consistently locked. If the TC clutch status shows unlocking/locking, look to see if the TPS volts are fluctuating by 0.2 volts or more. It the conditions are met, perform the Repair Procedure. If a surge like condition is felt but the above test does not confirm the TCC unlocking/locking occurrence, further diagnosis and testing will be required. NOTE: WHENEVER A POWERTRAIN CONTROL MODULE (PCM) IS REPLACED DUE TO FAILURE, THE SOFTWARE OF THE REPLACEMENT CONTROLLER MUST BE VERIFIED FOR THE LATEST REVISION LEVEL. USE THE FLASH PROCEDURE TO UPDATE REPLACED CONTROLLERS AS NECESSARY. PARTS REQUIRED: 1 04669020 Label, Authorized Software Update 1 04275086 Label, Authorized Modification EQUIPMENT REQUIRED: 1 CH6000 Scan Tool (DRB III(R)) 1 CH7035 General Purpose Interface Bus Cable (GPIB) 1 CH7000/7001 J1962 Cable 1 MDS1 or MDS2 NOTE: THE MDS1/MDS2 AND DRB III(R) ARE REQUIRED TO PERFORM PART OF THIS REPAIR. IF USING THE MDS1 AND DRB III(R) THE MDS MUST BE OPERATING AT RELEASE 21 OR HIGHER AND TIL CD RELEASE 1179 OR HIGHER MUST BE INSTALLED. IF USING THE MDS2 AND DRB III(R) THE SYSTEM MUST BE OPERATING AT CIS CD2030 OR HIGHER. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Throttle Position Sensor: > 18-02-99 > Feb > 99 > Torque Converter Clutch Erratic Operation > Page 1064 POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-42-95 0.5 Hrs. FAILURE CODE: FM - Flash Module MDS1 Procedure 1. Connect the MDS1 (Mopar Diagnostic System) and DRB III(R) (Scan Tool) to the vehicle and power them up. 2. Use the arrow keys and select # 2 CONNECT TO MDS1 OR MDS2 on the DRB III(R) MAIN MENU SCREEN. 3. Use the arrow keys and select MDS DIAGNOSTICS OR DRB III(R) UPDATE on the DRB III(R) MAIN MENU SCREEN. 4. Use the arrow keys and select DIAGNOSTIC MENU on the MDS1, then press NEXT MENU. 5. Use the arrow keys and select VEHICLE CONTROLLER PROGRAMMING on the MDS1, then press NEXT MENU. 6. Use the arrow keys and select PROGRAMMING OF ALL OTHER CONTROLLERS USING THE MDS1 & DRB III(R) on the MDS, then press NEXT MENU. 7. Follow the steps presented on the MDS1 and DRB III(R) that will allow the DRB III(R) to obtain the current part number of the PCM. 8. The MDS1 will display the vehicle's PCM part number and the replacement part number(s). Press NEXT MENU to begin programming. NOTE: A NO UPDATES AVAILABLE MESSAGE MAY BE DISPLAYED. CHECK THE PCM PART NUMBER ON THE VEHICLE AND COMPARE IT TO THE PART NUMBER DISPLAYED ON THE MDS. IF NO UPDATES ARE AVAILABLE, FIRST CHECK YOUR DIAGNOSTIC EQUIPMENT FOR THE LATEST SOFTWARE LEVELS AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION. 9. The MDS1 and DRB III(R) will prompt for any operator action needed during the remainder of the reprogramming process. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. 10. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Figure 1). Attach the label to the PCM and cover the label with the clear plastic overlay. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Throttle Position Sensor: > 18-02-99 > Feb > 99 > Torque Converter Clutch Erratic Operation > Page 1065 11. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI label (Figure 2). MDS2 Procedures 1. Log onto the MDS2 system. 2. Connect the MDS2 (Mopar Diagnostic System) and DRB III(R) (Scan Tool) to the vehicle and switch the ignition key to "ON". 3. Use the arrow keys and select # 2 CONNECT TO MDS1 OR MDS2 on the DRB III(R) MAIN MENU SCREEN. 4. Use the arrow keys and select # 2 RUN MDS2 APPLICATION on the DRB III(R) MAIN MENU SCREEN. NOTE: ONCE MDS2, DRB III(R), AND VEHICLE COMMUNICATION HAS BEEN ESTABLISHED, THE CANNOT READ VIN FROM DRB III(R) MESSAGE (ON THE MDS2) WILL BE REPLACED BY THE VEHICLE VIN. PRESS THE "OK" BUTTON ON THE MDS2 TO REQUEST A MDS2 SESSION FOR THE VEHICLE VIN INDICATED. PRESS THE "OK" BUTTON WHEN ASKED TO BEGIN SESSION. 5. Push the FLASH tab on the MDS2. NOTE: A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION. 6. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. NOTE: A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION. 7. Select the new software part number with the light pen and click UPDATE CONTROLLER SOFTWARE. 8. The MDS2 and DRB III(R) will prompt for any operator action needed during the remainder of the reprogramming process. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. 9. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Figure 1). Attach the label to the PCM and cover the label with the clear plastic overlay. 10. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI label (Figure 2). Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 1066 Throttle Position Sensor: Service and Repair Refer to Accelerator Pedal Position Sensor. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 1070 Transmission Position Switch/Sensor: Service and Repair Park/Neutral Position Switch 1. Raise vehicle and position drain pan under switch. 2. Disconnect switch wires. 3. Remove switch from case. 4. Move shift lever to Park and Neutral positions. Verify that switch operating lever fingers are centered in switch opening in case. 5. Install new seal on switch and install switch in case. Tighten switch to 34 Nm (25 ft. lbs.) torque. 6. Test continuity of new switch with 12V test lamp. 7. Connect switch wires and lower vehicle. 8. Top off transmission fluid level. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions Vehicle Speed Sensor: Diagram Information and Instructions Introduction General Information (Part 1 Of 2) Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1075 General Information (Part 2 Of 2) Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Function Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1076 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1077 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1078 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1079 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1080 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1081 Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1082 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1083 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1084 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1085 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1086 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Terminal/Connector Repair-Thomas and Betts Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1087 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector. Removing Wire Terminal 4. Insert the probe end of Special Tool 6934 into the back of the connector cavity. 5. Grasp the wire and Special Tool 6934 and slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal. 7. Install the wire and terminal in the connector. Fully seat the terminal in the connector. Single Lock Tab 8. Push in the single lock tab on the side of the connector. Wiring Repair Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1088 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1089 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1090 Vehicle Speed Sensor: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1091 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1092 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Page 1093 Vehicle Speed Sensor: Description and Operation The Vehicle Speed Sensor (VSS) is no longer used for any Dodge Truck. Vehicle speed and distance covered are measured by the Rear Wheel Speed Sensor. The sensor is mounted to the rear axle. A signal is sent from this sensor to the Controller Antilock Brake (CAB) computer. A signal is then sent from the CAB to the Powertrain Control Module (PCM) to determine vehicle speed and distance covered. The PCM will then determine strategies for speed control system operation. Testing for the Rear Wheel Speed Sensor can be found at Antilock Brakes / Traction Control Systems. See: Brakes and Traction Control/Antilock Brakes / Traction Control Systems/Testing and Inspection All other testing for the Vehicle Speed Signal can be found at Computers and Control Systems. See: Powertrain Management/Computers and Control Systems/Testing and Inspection Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Specifications Accelerator Pedal Position Sensor: Specifications Accelerator Pedal Position Sensor Bracket Bolts 12 Nm Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Specifications > Page 1098 APPS Assembly, Lever, Mounting Bolts(6), Wire Harness Clip, Calibration Screws (No Adjustment) Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Specifications > Page 1099 Accelerator Pedal Position Sensor: Description and Operation ACCELERATOR PEDAL POSITION SENSOR (APPS)-ECM INPUT The Accelerator Pedal Position Sensor (APPS) is a linear potentiometer. It provides the Engine Control Module (ECM) with a DC voltage signal proportional to the angle, or position of the accelerator pedal. In previous model years, this part was known as the Throttle Position Sensor (TPS). Diesel engines used in previous model years used a mechanical cable between the accelerator pedal and the TPS lever. Linkage and bellcranks between the TPS cable lever and the fuel injection pump were also used. Although the cable has been retained with the APPS, the linkage and bellcranks between the cable lever and the fuel injection pump are no longer used. APPS Assembly Location APPS Sensor Location (Rear View) The APPS assembly is located at the top-left-front of the engine. A plastic cover is used to cover the assembly. The actual sensor is located behind its mounting bracket. The APPS is serviced (replaced) as one assembly including the lever, brackets and sensor. The APPS is calibrated and permanently positioned to its mounting bracket. CAUTION: Do not attempt to remove sensor from its mounting bracket as electronic calibration will be destroyed (sensor-to-bracket mounting screws are permanently attached). Two accelerator lever set screws are used to position lever. Do not attempt to alter positions of these set screws as electronic calibration will be destroyed. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Specifications > Page 1100 Accelerator Pedal Position Sensor: Service and Repair Cable/Lever/Linkage/Cover The APPS is serviced (replaced) as one assembly including the lever, brackets and sensor. The APPS is calibrated to its mounting bracket. The APPS assembly is located at left-front of engine below plastic cable/lever/linkage cover. APPS Assembly CAUTION: Do not attempt to remove sensor from its mounting bracket as electronic calibration will be destroyed (sensor-to-bracket mounting screws are permanently attached). Two accelerator lever set screws are used to position lever. Do not attempt to alter positions of these set screws as electronic calibration will be destroyed. REMOVAL 1. Disconnect both negative battery cables at both batteries. 2. Remove cable cover. Cable cover is attached with 2 Phillips screws, 2 plastic retention clips and 2 push tabs. Remove 2 Phillips screws and carefully pry out 2 retention clips. After clip removal, push rearward on front tab, and upward on lower tab for cover removal. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Specifications > Page 1101 Cables At Throttle Lever 3. Using finger pressure only, disconnect end of speed control servo cable from throttle lever pin by pulling forward on connector while holding lever rearward.DO NOT try to pull connector off perpendicular to lever pin. Connector will be broken. 4. Using two small screwdrivers, pry throttle cable connector socket from throttle lever ball. Be very careful not to bend throttle lever arm. 5. Disconnect transmission control cable at lever arm (if equipped). 6. Squeeze pinch tabs on speed control cable and pull cable rearward to remove from cable mounting bracket. 7. Squeeze pinch tabs on throttle cable and pull cable rearward to remove from cable mounting bracket. 8. If equipped with an automatic transmission, refer to Transmission for transmission control cable removal procedures. 9. Disconnect wiring harness clip at bottom of bracket. Electrical Connector At Bottom Of APPS 10. Remove 6 mounting bolts and partially remove APPS assembly from engine. After assembly is partially removed, disconnect electrical connector from bottom of sensor by pushing on connector tab. 11. Remove APPS assembly from engine. INSTALLATION 1. Snap electrical connector into bottom of sensor. 2. Position APPS assembly to engine and install 6 bolts. Tighten bolts to 12 Nm (105 in. lbs.) torque. 3. Connect wiring harness clip at bottom of bracket. 4. If equipped with an automatic transmission, refer to Transmission for transmission control cable installation procedures. 5. Install speed control cable into mounting bracket. Be sure pinch tabs have secured cable. 6. Install throttle cable into mounting bracket. Be sure pinch tabs have secured cable. 7. Connect throttle cable at lever (snaps on). 8. Connect speed control cable to lever by pushing cable connector rearward onto lever pin while holding lever forward. 9. Install cable cover. 10. Connect both negative battery cables to both batteries. 11. ECM Calibration: Turn key to ON position. Without starting engine, slowly press throttle pedal to floor and then slowly release. This step must be Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Specifications > Page 1102 done (one time) to ensure accelerator pedal position sensor calibration has been learned by ECM. If not done, possible DTC's may be set. 12. Use DRB scan tool to erase any DTC's from ECM/PCM. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Locations Fuel Temperature Sensor: Locations One of the sensors is located inside of the Bosch VP44 fuel injection pump. The other fuel temperature sensor is located in the top of the fuel filter housing. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Locations > Page 1106 Fuel Temperature Sensor: Description and Operation Two different fuel temperature sensors are used. One of the sensors is located inside of the Bosch VP44 fuel injection pump and is a non-serviceable part. It is used to check fuel temperature within the injection pump and to set a Diagnostic Trouble Code (DTC) if a specific high fuel temperature has been reached. If high temperature has been reached, engine power will be de-rated by the Engine Control Module (ECM). The other fuel temperature sensor is located in the top of the fuel filter housing and is serviceable (serviceable if replacing the fuel heater). It is used to control the fuel heater element. Refer to Fuel Heater Description and Operation for additional information. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 18-02-99 > Feb > 99 > Torque Converter Clutch - Erratic Operation Technical Service Bulletin # 18-02-99 Date: 990219 Torque Converter Clutch - Erratic Operation NUMBER: 18-02-99 GROUP: Vehicle Performance DATE: Feb. 19, 1999 SUBJECT: Erratic Torque Converter Clutch (TCC) Operation (5.9L Diesel Applications) OVERVIEW: This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software (calibration changes 98cal12 & 99cal14). MODELS: 1998 - 1999 (BR/BE) Ram Truck NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A 5.9L 24 VALVE DIESEL ENGINE AND AUTOMATIC TRANSMISSION BUILT BETWEEN JAN. 1, 1998 AND DEC. 18, 1998 (MDH 0101XX & 1218XX). SYMPTOM/CONDITION: Some vehicles may experience a surge like condition while in 4th gear. This may be caused by the Torque Converter Clutch (TCC) unlocking and locking when it should be consistently locked. The cause of this erratic operation has been identified as electrical noise from the Throttle Position Sensor (TPS) or Alternator. DIAGNOSIS: Using the Mopar Diagnostic System (MDS/MDS2) and or the Diagnostic Scan Tool (DRB III(R)) with the appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. Verify the condition by creating a custom display in the DRB III(R) and include the following: SENSORS (Output Shaft Speed, TPS Volts, Trans Temp Degree) & INPUTS/OUTPUTS (Brake Switch, Park/Neutral, ASD Relay Sense, Desired TC Clutch). Drive the vehicle with a helper monitoring the DRB III(R). Warm the engine and verify the transmission fluid temperature is greater than 32°F and consistent. Operate the vehicle with an output shaft speed greater than 2200 rpm. Verify that the brake switch shows a released status that is consistent and verify the park/neutral status reads D/R and is consistent. While keeping the output shaft speed above 2200 rpm, hold the throttle so the TPS reads 1 volt. Monitor the TC clutch status, it should be consistently locked. If the TC clutch status shows unlocking/locking, look to see if the TPS volts are fluctuating by 0.2 volts or more. It the conditions are met, perform the Repair Procedure. If a surge like condition is felt but the above test does not confirm the TCC unlocking/locking occurrence, further diagnosis and testing will be required. NOTE: WHENEVER A POWERTRAIN CONTROL MODULE (PCM) IS REPLACED DUE TO FAILURE, THE SOFTWARE OF THE REPLACEMENT CONTROLLER MUST BE VERIFIED FOR THE LATEST REVISION LEVEL. USE THE FLASH PROCEDURE TO UPDATE REPLACED CONTROLLERS AS NECESSARY. PARTS REQUIRED: 1 04669020 Label, Authorized Software Update 1 04275086 Label, Authorized Modification EQUIPMENT REQUIRED: 1 CH6000 Scan Tool (DRB III(R)) 1 CH7035 General Purpose Interface Bus Cable (GPIB) 1 CH7000/7001 J1962 Cable 1 MDS1 or MDS2 NOTE: THE MDS1/MDS2 AND DRB III(R) ARE REQUIRED TO PERFORM PART OF THIS REPAIR. IF USING THE MDS1 AND DRB III(R) THE MDS MUST BE OPERATING AT RELEASE 21 OR HIGHER AND TIL CD RELEASE 1179 OR HIGHER MUST BE INSTALLED. IF USING THE MDS2 AND DRB III(R) THE SYSTEM MUST BE OPERATING AT CIS CD2030 OR HIGHER. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 18-02-99 > Feb > 99 > Torque Converter Clutch - Erratic Operation > Page 1115 POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-42-95 0.5 Hrs. FAILURE CODE: FM - Flash Module MDS1 Procedure 1. Connect the MDS1 (Mopar Diagnostic System) and DRB III(R) (Scan Tool) to the vehicle and power them up. 2. Use the arrow keys and select # 2 CONNECT TO MDS1 OR MDS2 on the DRB III(R) MAIN MENU SCREEN. 3. Use the arrow keys and select MDS DIAGNOSTICS OR DRB III(R) UPDATE on the DRB III(R) MAIN MENU SCREEN. 4. Use the arrow keys and select DIAGNOSTIC MENU on the MDS1, then press NEXT MENU. 5. Use the arrow keys and select VEHICLE CONTROLLER PROGRAMMING on the MDS1, then press NEXT MENU. 6. Use the arrow keys and select PROGRAMMING OF ALL OTHER CONTROLLERS USING THE MDS1 & DRB III(R) on the MDS, then press NEXT MENU. 7. Follow the steps presented on the MDS1 and DRB III(R) that will allow the DRB III(R) to obtain the current part number of the PCM. 8. The MDS1 will display the vehicle's PCM part number and the replacement part number(s). Press NEXT MENU to begin programming. NOTE: A NO UPDATES AVAILABLE MESSAGE MAY BE DISPLAYED. CHECK THE PCM PART NUMBER ON THE VEHICLE AND COMPARE IT TO THE PART NUMBER DISPLAYED ON THE MDS. IF NO UPDATES ARE AVAILABLE, FIRST CHECK YOUR DIAGNOSTIC EQUIPMENT FOR THE LATEST SOFTWARE LEVELS AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION. 9. The MDS1 and DRB III(R) will prompt for any operator action needed during the remainder of the reprogramming process. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. 10. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Figure 1). Attach the label to the PCM and cover the label with the clear plastic overlay. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 18-02-99 > Feb > 99 > Torque Converter Clutch - Erratic Operation > Page 1116 11. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI label (Figure 2). MDS2 Procedures 1. Log onto the MDS2 system. 2. Connect the MDS2 (Mopar Diagnostic System) and DRB III(R) (Scan Tool) to the vehicle and switch the ignition key to "ON". 3. Use the arrow keys and select # 2 CONNECT TO MDS1 OR MDS2 on the DRB III(R) MAIN MENU SCREEN. 4. Use the arrow keys and select # 2 RUN MDS2 APPLICATION on the DRB III(R) MAIN MENU SCREEN. NOTE: ONCE MDS2, DRB III(R), AND VEHICLE COMMUNICATION HAS BEEN ESTABLISHED, THE CANNOT READ VIN FROM DRB III(R) MESSAGE (ON THE MDS2) WILL BE REPLACED BY THE VEHICLE VIN. PRESS THE "OK" BUTTON ON THE MDS2 TO REQUEST A MDS2 SESSION FOR THE VEHICLE VIN INDICATED. PRESS THE "OK" BUTTON WHEN ASKED TO BEGIN SESSION. 5. Push the FLASH tab on the MDS2. NOTE: A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION. 6. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. NOTE: A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION. 7. Select the new software part number with the light pen and click UPDATE CONTROLLER SOFTWARE. 8. The MDS2 and DRB III(R) will prompt for any operator action needed during the remainder of the reprogramming process. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. 9. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Figure 1). Attach the label to the PCM and cover the label with the clear plastic overlay. 10. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI label (Figure 2). Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-04-98 > Sep > 98 > Accessory Drive Belt - Noisy/Damaged Drive Belt: All Technical Service Bulletins Accessory Drive Belt - Noisy/Damaged NO: 09-04-98 GROUP: Engine DATE: Sep. 25, 1998 SUBJECT: Accessory Drive Belt Noise Or Damage/Crank Pulley Bolt Loose MODELS: 1994 - 1999 (BR/BE) Ram Truck NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH AN 8.0L ENGINE. SYMPTOM/CONDITION: Some vehicles may exhibit a condition where the accessory drive belt becomes damaged on the inboard edge. Customers may explain the problem as belt noise. This may be caused by the crank pulley loosening on the crank and causing a misalignment. DIAGNOSIS: Inspect the accessory drive belt for fraying or unusual wear on the inboard edge. If wear is noted, inspect the crank pulley bolt for looseness and the crank pulley for misalignment. Sight the crank pulley with other accessory drives or use a straight edge to detect misalignment. If the crank pulley is misaligned or bolt is loose, perform the Repair Procedure. PARTS REQUIRED: 1 53041067 Belt, Accessory Drive 1994 - 1996 Models W/AC Federal 1 53041163 Belt, Accessory Drive 1994 - 1996 Models W/AC California 1 53041068 Belt, Accessory Drive 1994 - 1996 Models WO/AC Federal 1 53041164 Belt, Accessory Drive 1994 - 1996 Models WO/AC California 1 53041116 Belt, Accessory Drive 1997 - 1999 Models WO/AC Federal 1 53041117 Belt, Accessory Drive 1997 - 1999 Models WO/AC California 1 53041115 Belt, Accessory Drive 1997 - 1999 Models W/AC All 1 04318032 Adhesive, Stud and Bearing Mount REPAIR PROCEDURE: This bulletin involves removing the crank pulley bolt, checking the press fit of the pulley, reinstalling the bolt using thread locker, and replacing the accessory drive belt. 1. Disconnect the negative battery cable. 2. Remove the accessory drive belt following service manual procedures. 3. Drain and remove the radiator following all service manual warnings/cautions and procedures. NOTE: DRAIN THE COOLANT INTO A CLEAN DRAIN PAN. 4. Remove the bolt attaching the crankshaft pulley damper to the crankshaft. 5. Using your hands, pull on the crankshaft pulley damper to test the press fit to the crank shaft. The pulley should be tight and not come off the crank with hand pressure. NOTE: IF THE CRANK PULLEY DAMPER IS LOOSE (NO PRESS FIT) REPLACE THE CRANK PULLEY DAMPER WITH P/N 53020776. 6. Use Miller Tool C-3688 and fully press the crankshaft pulley damper onto the crankshaft. 7. Add thread locker p/n 04318032 to the end 3 or 4 threads of the crank pulley bolt. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-04-98 > Sep > 98 > Accessory Drive Belt - Noisy/Damaged > Page 1122 8. Install the bolt and torque it to 312 Nm (230 ft. lbs.). NOTE: USE A BAR TO LOCK THE PULLEY IN PLACE WHILE TIGHTENING. 9. Install a new accessory drive belt following service manual procedures. 10. Reinstall the radiator following service manual procedures. 11. Reinstall the negative battery cable. 12. Fill the cooling system with the saved coolant and operate the vehicle to purge air from the system. Top off the automatic transmission fluid (if required). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 09-25-25-90 1.5 Hrs. FAILURE CODE: P8 - New Part Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Throttle Position Sensor: > 08-32-99 > Oct > 99 > Customer Interest for Throttle Position Sensor: > 18-02-99 > Feb > 99 > Torque Converter Clutch - Erratic Operation Technical Service Bulletin # 18-02-99 Date: 990219 Torque Converter Clutch - Erratic Operation NUMBER: 18-02-99 GROUP: Vehicle Performance DATE: Feb. 19, 1999 SUBJECT: Erratic Torque Converter Clutch (TCC) Operation (5.9L Diesel Applications) OVERVIEW: This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software (calibration changes 98cal12 & 99cal14). MODELS: 1998 - 1999 (BR/BE) Ram Truck NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A 5.9L 24 VALVE DIESEL ENGINE AND AUTOMATIC TRANSMISSION BUILT BETWEEN JAN. 1, 1998 AND DEC. 18, 1998 (MDH 0101XX & 1218XX). SYMPTOM/CONDITION: Some vehicles may experience a surge like condition while in 4th gear. This may be caused by the Torque Converter Clutch (TCC) unlocking and locking when it should be consistently locked. The cause of this erratic operation has been identified as electrical noise from the Throttle Position Sensor (TPS) or Alternator. DIAGNOSIS: Using the Mopar Diagnostic System (MDS/MDS2) and or the Diagnostic Scan Tool (DRB III(R)) with the appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. Verify the condition by creating a custom display in the DRB III(R) and include the following: SENSORS (Output Shaft Speed, TPS Volts, Trans Temp Degree) & INPUTS/OUTPUTS (Brake Switch, Park/Neutral, ASD Relay Sense, Desired TC Clutch). Drive the vehicle with a helper monitoring the DRB III(R). Warm the engine and verify the transmission fluid temperature is greater than 32°F and consistent. Operate the vehicle with an output shaft speed greater than 2200 rpm. Verify that the brake switch shows a released status that is consistent and verify the park/neutral status reads D/R and is consistent. While keeping the output shaft speed above 2200 rpm, hold the throttle so the TPS reads 1 volt. Monitor the TC clutch status, it should be consistently locked. If the TC clutch status shows unlocking/locking, look to see if the TPS volts are fluctuating by 0.2 volts or more. It the conditions are met, perform the Repair Procedure. If a surge like condition is felt but the above test does not confirm the TCC unlocking/locking occurrence, further diagnosis and testing will be required. NOTE: WHENEVER A POWERTRAIN CONTROL MODULE (PCM) IS REPLACED DUE TO FAILURE, THE SOFTWARE OF THE REPLACEMENT CONTROLLER MUST BE VERIFIED FOR THE LATEST REVISION LEVEL. USE THE FLASH PROCEDURE TO UPDATE REPLACED CONTROLLERS AS NECESSARY. PARTS REQUIRED: 1 04669020 Label, Authorized Software Update 1 04275086 Label, Authorized Modification EQUIPMENT REQUIRED: 1 CH6000 Scan Tool (DRB III(R)) 1 CH7035 General Purpose Interface Bus Cable (GPIB) 1 CH7000/7001 J1962 Cable 1 MDS1 or MDS2 NOTE: THE MDS1/MDS2 AND DRB III(R) ARE REQUIRED TO PERFORM PART OF THIS REPAIR. IF USING THE MDS1 AND DRB III(R) THE MDS MUST BE OPERATING AT RELEASE 21 OR HIGHER AND TIL CD RELEASE 1179 OR HIGHER MUST BE INSTALLED. IF USING THE MDS2 AND DRB III(R) THE SYSTEM MUST BE OPERATING AT CIS CD2030 OR HIGHER. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Throttle Position Sensor: > 08-32-99 > Oct > 99 > Customer Interest for Throttle Position Sensor: > 18-02-99 > Feb > 99 > Torque Converter Clutch - Erratic Operation > Page 1132 POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-42-95 0.5 Hrs. FAILURE CODE: FM - Flash Module MDS1 Procedure 1. Connect the MDS1 (Mopar Diagnostic System) and DRB III(R) (Scan Tool) to the vehicle and power them up. 2. Use the arrow keys and select # 2 CONNECT TO MDS1 OR MDS2 on the DRB III(R) MAIN MENU SCREEN. 3. Use the arrow keys and select MDS DIAGNOSTICS OR DRB III(R) UPDATE on the DRB III(R) MAIN MENU SCREEN. 4. Use the arrow keys and select DIAGNOSTIC MENU on the MDS1, then press NEXT MENU. 5. Use the arrow keys and select VEHICLE CONTROLLER PROGRAMMING on the MDS1, then press NEXT MENU. 6. Use the arrow keys and select PROGRAMMING OF ALL OTHER CONTROLLERS USING THE MDS1 & DRB III(R) on the MDS, then press NEXT MENU. 7. Follow the steps presented on the MDS1 and DRB III(R) that will allow the DRB III(R) to obtain the current part number of the PCM. 8. The MDS1 will display the vehicle's PCM part number and the replacement part number(s). Press NEXT MENU to begin programming. NOTE: A NO UPDATES AVAILABLE MESSAGE MAY BE DISPLAYED. CHECK THE PCM PART NUMBER ON THE VEHICLE AND COMPARE IT TO THE PART NUMBER DISPLAYED ON THE MDS. IF NO UPDATES ARE AVAILABLE, FIRST CHECK YOUR DIAGNOSTIC EQUIPMENT FOR THE LATEST SOFTWARE LEVELS AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION. 9. The MDS1 and DRB III(R) will prompt for any operator action needed during the remainder of the reprogramming process. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. 10. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Figure 1). Attach the label to the PCM and cover the label with the clear plastic overlay. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Throttle Position Sensor: > 08-32-99 > Oct > 99 > Customer Interest for Throttle Position Sensor: > 18-02-99 > Feb > 99 > Torque Converter Clutch - Erratic Operation > Page 1133 11. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI label (Figure 2). MDS2 Procedures 1. Log onto the MDS2 system. 2. Connect the MDS2 (Mopar Diagnostic System) and DRB III(R) (Scan Tool) to the vehicle and switch the ignition key to "ON". 3. Use the arrow keys and select # 2 CONNECT TO MDS1 OR MDS2 on the DRB III(R) MAIN MENU SCREEN. 4. Use the arrow keys and select # 2 RUN MDS2 APPLICATION on the DRB III(R) MAIN MENU SCREEN. NOTE: ONCE MDS2, DRB III(R), AND VEHICLE COMMUNICATION HAS BEEN ESTABLISHED, THE CANNOT READ VIN FROM DRB III(R) MESSAGE (ON THE MDS2) WILL BE REPLACED BY THE VEHICLE VIN. PRESS THE "OK" BUTTON ON THE MDS2 TO REQUEST A MDS2 SESSION FOR THE VEHICLE VIN INDICATED. PRESS THE "OK" BUTTON WHEN ASKED TO BEGIN SESSION. 5. Push the FLASH tab on the MDS2. NOTE: A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION. 6. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. NOTE: A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION. 7. Select the new software part number with the light pen and click UPDATE CONTROLLER SOFTWARE. 8. The MDS2 and DRB III(R) will prompt for any operator action needed during the remainder of the reprogramming process. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. 9. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Figure 1). Attach the label to the PCM and cover the label with the clear plastic overlay. 10. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI label (Figure 2). Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Drive Belt: > 18-02-99 > Feb > 99 > Torque Converter Clutch - Erratic Operation Technical Service Bulletin # 18-02-99 Date: 990219 Torque Converter Clutch - Erratic Operation NUMBER: 18-02-99 GROUP: Vehicle Performance DATE: Feb. 19, 1999 SUBJECT: Erratic Torque Converter Clutch (TCC) Operation (5.9L Diesel Applications) OVERVIEW: This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software (calibration changes 98cal12 & 99cal14). MODELS: 1998 - 1999 (BR/BE) Ram Truck NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A 5.9L 24 VALVE DIESEL ENGINE AND AUTOMATIC TRANSMISSION BUILT BETWEEN JAN. 1, 1998 AND DEC. 18, 1998 (MDH 0101XX & 1218XX). SYMPTOM/CONDITION: Some vehicles may experience a surge like condition while in 4th gear. This may be caused by the Torque Converter Clutch (TCC) unlocking and locking when it should be consistently locked. The cause of this erratic operation has been identified as electrical noise from the Throttle Position Sensor (TPS) or Alternator. DIAGNOSIS: Using the Mopar Diagnostic System (MDS/MDS2) and or the Diagnostic Scan Tool (DRB III(R)) with the appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. Verify the condition by creating a custom display in the DRB III(R) and include the following: SENSORS (Output Shaft Speed, TPS Volts, Trans Temp Degree) & INPUTS/OUTPUTS (Brake Switch, Park/Neutral, ASD Relay Sense, Desired TC Clutch). Drive the vehicle with a helper monitoring the DRB III(R). Warm the engine and verify the transmission fluid temperature is greater than 32°F and consistent. Operate the vehicle with an output shaft speed greater than 2200 rpm. Verify that the brake switch shows a released status that is consistent and verify the park/neutral status reads D/R and is consistent. While keeping the output shaft speed above 2200 rpm, hold the throttle so the TPS reads 1 volt. Monitor the TC clutch status, it should be consistently locked. If the TC clutch status shows unlocking/locking, look to see if the TPS volts are fluctuating by 0.2 volts or more. It the conditions are met, perform the Repair Procedure. If a surge like condition is felt but the above test does not confirm the TCC unlocking/locking occurrence, further diagnosis and testing will be required. NOTE: WHENEVER A POWERTRAIN CONTROL MODULE (PCM) IS REPLACED DUE TO FAILURE, THE SOFTWARE OF THE REPLACEMENT CONTROLLER MUST BE VERIFIED FOR THE LATEST REVISION LEVEL. USE THE FLASH PROCEDURE TO UPDATE REPLACED CONTROLLERS AS NECESSARY. PARTS REQUIRED: 1 04669020 Label, Authorized Software Update 1 04275086 Label, Authorized Modification EQUIPMENT REQUIRED: 1 CH6000 Scan Tool (DRB III(R)) 1 CH7035 General Purpose Interface Bus Cable (GPIB) 1 CH7000/7001 J1962 Cable 1 MDS1 or MDS2 NOTE: THE MDS1/MDS2 AND DRB III(R) ARE REQUIRED TO PERFORM PART OF THIS REPAIR. IF USING THE MDS1 AND DRB III(R) THE MDS MUST BE OPERATING AT RELEASE 21 OR HIGHER AND TIL CD RELEASE 1179 OR HIGHER MUST BE INSTALLED. IF USING THE MDS2 AND DRB III(R) THE SYSTEM MUST BE OPERATING AT CIS CD2030 OR HIGHER. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Drive Belt: > 18-02-99 > Feb > 99 > Torque Converter Clutch - Erratic Operation > Page 1139 POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-42-95 0.5 Hrs. FAILURE CODE: FM - Flash Module MDS1 Procedure 1. Connect the MDS1 (Mopar Diagnostic System) and DRB III(R) (Scan Tool) to the vehicle and power them up. 2. Use the arrow keys and select # 2 CONNECT TO MDS1 OR MDS2 on the DRB III(R) MAIN MENU SCREEN. 3. Use the arrow keys and select MDS DIAGNOSTICS OR DRB III(R) UPDATE on the DRB III(R) MAIN MENU SCREEN. 4. Use the arrow keys and select DIAGNOSTIC MENU on the MDS1, then press NEXT MENU. 5. Use the arrow keys and select VEHICLE CONTROLLER PROGRAMMING on the MDS1, then press NEXT MENU. 6. Use the arrow keys and select PROGRAMMING OF ALL OTHER CONTROLLERS USING THE MDS1 & DRB III(R) on the MDS, then press NEXT MENU. 7. Follow the steps presented on the MDS1 and DRB III(R) that will allow the DRB III(R) to obtain the current part number of the PCM. 8. The MDS1 will display the vehicle's PCM part number and the replacement part number(s). Press NEXT MENU to begin programming. NOTE: A NO UPDATES AVAILABLE MESSAGE MAY BE DISPLAYED. CHECK THE PCM PART NUMBER ON THE VEHICLE AND COMPARE IT TO THE PART NUMBER DISPLAYED ON THE MDS. IF NO UPDATES ARE AVAILABLE, FIRST CHECK YOUR DIAGNOSTIC EQUIPMENT FOR THE LATEST SOFTWARE LEVELS AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION. 9. The MDS1 and DRB III(R) will prompt for any operator action needed during the remainder of the reprogramming process. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. 10. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Figure 1). Attach the label to the PCM and cover the label with the clear plastic overlay. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Drive Belt: > 18-02-99 > Feb > 99 > Torque Converter Clutch - Erratic Operation > Page 1140 11. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI label (Figure 2). MDS2 Procedures 1. Log onto the MDS2 system. 2. Connect the MDS2 (Mopar Diagnostic System) and DRB III(R) (Scan Tool) to the vehicle and switch the ignition key to "ON". 3. Use the arrow keys and select # 2 CONNECT TO MDS1 OR MDS2 on the DRB III(R) MAIN MENU SCREEN. 4. Use the arrow keys and select # 2 RUN MDS2 APPLICATION on the DRB III(R) MAIN MENU SCREEN. NOTE: ONCE MDS2, DRB III(R), AND VEHICLE COMMUNICATION HAS BEEN ESTABLISHED, THE CANNOT READ VIN FROM DRB III(R) MESSAGE (ON THE MDS2) WILL BE REPLACED BY THE VEHICLE VIN. PRESS THE "OK" BUTTON ON THE MDS2 TO REQUEST A MDS2 SESSION FOR THE VEHICLE VIN INDICATED. PRESS THE "OK" BUTTON WHEN ASKED TO BEGIN SESSION. 5. Push the FLASH tab on the MDS2. NOTE: A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION. 6. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. NOTE: A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION. 7. Select the new software part number with the light pen and click UPDATE CONTROLLER SOFTWARE. 8. The MDS2 and DRB III(R) will prompt for any operator action needed during the remainder of the reprogramming process. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. 9. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Figure 1). Attach the label to the PCM and cover the label with the clear plastic overlay. 10. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI label (Figure 2). Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 1141 Drive Belt: Description and Operation All vehicles are available with either a 3.9L V-6, a 5.2L V-8, two different 5.9L V-8 engines, an 8.0L V-10 or a 5.9L in-line 6 cylinder diesel engine. The accessory drive components are operated by a single, crankshaft driven, serpentine drive belt on all engines. An automatic belt tensioner is also used to maintain correct belt tension at all times. This is used on all engines. Refer to Drive Belt Tensioner. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications Camshaft Position Sensor: Specifications Camshaft Position Sensor (CMP) Bolt 20 Nm Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 1146 Camshaft Position Sensor: Locations Camshaft Position Sensor (CMP) Location The camshaft position sensor (CMP) is located below the fuel injection pump. It is attached to the back of the timing gear cover housing. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 1147 Connector View Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 1148 Camshaft Position Sensor: Description and Operation CAMSHAFT POSITION SENSOR (CMP)-ECM INPUT Camshaft Position Sensor (CMP) The Camshaft Position Sensor (CMP) contains a hall effect device called a sync signal generator to generate a sync signal. The sync signal generator detects a machined hole on the rear face of the camshaft drive gear. The signal is used to verify the position of the #1 cylinder during engine operation. When the leading edge of the machined hole enters the tip of the CMP the interruption of magnetic field causes the voltage to switch high resulting in a signal of approximately 5 volts. When the trailing edge of the machined hole leaves the tip of the CMP the change of the magnetic field causes the voltage to switch low to 0 volts. Camshaft Position Sensor (CMP) Location The CMP is located below the fuel injection pump. It is attached to the back of the timing gear cover housing. The CMP is not used for any control of fuel system. It is used only for diagnostic purposes. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 1149 Camshaft Position Sensor: Service and Repair Camshaft Position Sensor (CMP) Location The camshaft position sensor (CMP) is located below the fuel injection pump. It is attached to the back of the timing gear cover housing. REMOVAL 1. Disconnect both negative cables from both batteries. 2. Clean area around CMP. 3. Disconnect electrical at CMP. Camshaft Position Sensor (CMP) Removal/Installation 4. Remove CMP mounting bolt. Bolt head is female-hex. 5. Remove CMP from engine by twisting and pulling straight back. 6. Discard CMP O-ring. INSTALLATION 1. Install new O-ring to CMP. Apply clean engine oil to O-ring. 2. Clean area around CMP mounting hole. 3. To prevent tearing O-ring, install CMP into gear housing using a twisting action. 4. Install mounting bolt and tighten to 20 Nm (15 ft. lbs.) torque. 5. Install electrical connector to CMP. 6. Connect both negative cables to both batteries. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Locations Ignition Switch Lock Cylinder: Locations The Key-In-Switch is located in the ignition switch module. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Locations > Page 1154 Ignition Switch Lock Cylinder: Description and Operation IGNITION SWITCH AND KEY LOCK CYLINDER The ignition switch is located on the steering column. The Key-In-Switch is located in the ignition switch module. For removal/installation of either the key lock cylinder or ignition switch, refer to Ignition Switch and Key Cylinder Removal/Installation. On vehicles equipped with an automatic transmission and a steering column mounted shifter an interlock device is located within the steering column. This interlock device is used to lock the transmission shifter in the PARK position when the key is in the LOCKED or ACCESSORY position. The interlock device within the steering column is not serviceable. If repair is necessary, the steering column assembly must be replaced. On vehicles equipped with an automatic transmission and a floor mounted shifter, a cable connects the interlock device within the steering column assembly, to the transmission floor shift lever. This interlock device is used to lock the transmission shifter in the PARK position when the key is in the LOCKED or ACCESSORY position. The interlock device within the steering column is not serviceable. If repair is necessary, the steering column assembly must be replaced. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Locations > Page 1155 Ignition Switch Lock Cylinder: Service and Repair The ignition key must be in the key cylinder for cylinder removal. REMOVAL 1. Disconnect negative cable from battery. 2. If equipped with tilt column, remove tilt lever by turning it counterclockwise. Shroud Removal/Installation - Typical 3. Remove upper and lower covers (shrouds) from steering column. 4. If equipped with automatic transmission, place shifter in PARK position. Retaining Pin 5. A retaining pin is located at side of key cylinder assembly. a. Rotate key to RUN position. b. Press in on retaining pin while pulling key cylinder from ignition switch. INSTALLATION If installing ignition key lock cylinder only, proceed to following steps 2, 3 and 4. Also refer to following steps 12 through 18. If installing both switch and key cylinder, refer to steps 1 through 18. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Locations > Page 1156 Flag In RUN Position Key Cylinder Rear View 1. Rotate flag on rear of ignition switch until in RUN position. This step must be done to allow tang on key cylinder to fit into slots within ignition switch. Installing Key Cylinder Into Switch 2. With key into ignition key cylinder, rotate key clockwise until retaining pin can be depressed . Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Locations > Page 1157 3. Install key cylinder into ignition switch by aligning retaining pin into retaining pin slot. Push key cylinder into switch until retaining pin engages. After pin engages, rotate key to OFF or LOCK position. 4. Check for proper retention of key cylinder by attempting to pull cylinder from switch. Ignition Switch View From Column Park Lock Linkage - Automatic Transmission - Typical 5. Automatic Transmission Only: Before attaching ignition switch to steering column, the transmission shifter must be in PARK position. The park lock dowel pin on rear of ignition switch must also be properly indexed into the park lock linkage before installing switch. Steering Wheel Lock Lever Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Locations > Page 1158 6. The flag at rear of ignition switch must be properly indexed into steering column before installing switch. This flag is used to operate the steering wheel lock lever in steering column. This lever allows steering wheel position to be locked when key switch is in LOCK position. 7. Place ignition switch in LOCK position. The switch is in the LOCK position when column lock flag is parallel to ignition switch terminals. 8. Automatic Transmission Only: Apply a light coating of grease to park lock dowel pin and park lock slider linkage. Before installing switch, push the park lock slider linkage forward until it bottoms. Do a final positioning by pulling it rearward about one-quarter inch. 9. Apply a light coating of grease to both column lock flag and shaft at end of flag. 10. Place ignition switch into openings on steering column. a. Automatic Transmission Only: Be sure park lock dowel pin on rear of ignition switch enters slot in park lock slider linkage. b. Be sure flag on rear of switch is positioned above steering wheel lock lever. c. Align dowel pins on rear of switch into holes on side of steering column. d. Install 3 ignition switch mounting screws. Tighten screws to 3 Nm ± 0.5 Nm (26 in. lbs. ± 4 in. lbs.) torque. 11. Connect electrical connectors to ignition switch and halo lamp. Make sure that switch locking tabs are fully seated in wiring connectors. 12. Install steering column covers (shrouds). tighten screws to 2 Nm (17 in. lbs.) torque. 13. Install tilt column lever (if equipped). 14. Connect negative cable to battery. 15. Check for proper operation of halo light. 16. Automatic Transmission Only: Shifter should lock in PARK position when key is in LOCK position (if equipped with shift lock device). Shifter should unlock when key rotated to ON position. 17. Check for proper operation of ignition switch in ACCESSORY, LOCK, OFF; ON, RUN, and START positions. 18. Steering wheel should lock when key is in LOCK position. Rotate steering wheel to verify. Steering wheel should unlock when key is rotated to ON position. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches Air Bag Deactivation Switch: Technical Service Bulletins Air Bag - On/Off Switches NUMBER: 08-025-01 GROUP: Electrical DATE: Nov. 23, 2001 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-037-99, DATED NOVEMBER 12, 1999, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1999 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-00004). ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODELS, PARTS, AND 2001 MODEL YEAR PROCEDURES. NOTE: THIS BULLETIN DOES NOT APPLY TO DIAMLERCHRYSLER CANADA DEALERS. SUBJECT: Airbag On-Off Switches MODELS: 1990 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan 1995 - **2001** (AB) Ram Van/Wagon 1990 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) Lebaron Coupe/Convertible 1994 - **2001** (AN) Dakota 1990 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1991 - 1995 (AS) Town & Country/Caravan Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1994 - **2001** (BR/BE) Ram Pickup 1995 - 1996 (B7) Stealth 1998 - **2001** (DN) Durango 1995 - 2000 (FJ) Avenger/Sebring/Talon 1995 - 2000 (JA) Breeze/Cirrus/Stratus **2001** (JR) Sebring Sedan/Stratus Sedan/Sebring Convertible 1996 - 2000 (JX) Sebring Convertible 1993 - **2001** (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - **2001** (PL) Neon 1997 (PR) Prowler **2001 (PT) PT Cruiser** **2001** (RS) Town & Country/Caravan/Voyager Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 1164 1996 - 1997 (SR) Viper **2001 - 2002 (ST) Sebring Coupe/Stratus Coupe** 1997 - 2001** (TJ) Wrangler 1999 - **2001** (WJ) Grand Cherokee 1997 - **2001** (XJ) Cherokee 1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer NOTE: THIS BULLETIN IS PROVIDED TO IDENTIFY THE PARTS AND PROCEDURES NECESSARY TO DEACTIVATE AIRBAGS AUTHORIZED BY NHTSA. AIRBAG DEACTIVATION IS A CUSTOMER PAY PROCEDURE, NOT COVERED UNDER THE PROVISIONS OF THE WARRANTY. THE COMPONENT PARTS ARE COVERED UNDER THE APPROPRIATE MOPAR PART WARRANTY. NOTE: **SOME 2001 MODEL YEAR PACKAGES (AN/AN84/DN/JR/LH/PL/PT/RS/TJ) REQUIRE OCCUPANT RESTRAINT CONTROLLER (ORC) CONFIGURATION USING THE DRB III(R) AS DETAILED IN EACH VEHICLE SPECIFIC PACKAGE.** DISCUSSION: DaimlerChrysler Corporation is now offering airbag on-off switches for the selected vehicles listed above. The switches are packaged in a kit containing all necessary parts (except as indicated) and a detailed instruction sheet. Under the National Highway Traffic Safety Administration's rule, consumers will be authorized for on-off switches by claiming they meet any of several criteria. Airbag on-off switches must not be installed without the vehicle owner presenting the NHTSA authorization letter. For more information concerning the authorization process and/or the authorization letter call NHTSA's Auto Safety Hotline at 1-800-424-9393. We encourage you (dealer) to install these switches when the customer is interested in doing so and has the necessary NHTSA authorization. NOTE: FOR SOME 2000 MODEL YEAR APPLICATIONS (AB/AN/AN84/DN/JA/NS) **AND SOME 2001 CARRYOVER APPLICATIONS (AB/BR/WJ/XJ)**, A NEW OWNER'S MANUAL INSERT IS REQUIRED, P/N 05013528AA, AND MUST BE ORDERED IN ADDITION TO THE AIRBAG SWITCH KIT. THE NEW INSERT IS ORANGE, AND MUST BE PRESENTED TO THE CUSTOMER IN PLACE OF THE YELLOW ONE, P/N 05013517AA, THAT WILL COME IN THE AIRBAG KIT. **FOR SOME 2001 MODEL YEAR APPLICATIONS (WITH J1850 BUS, AN/AN84/DN/JR/LH/PL(PT/RS/TJ) A NEW OWNER'S MANUAL INSERT IS REQUIRED, P/N 05016025AA, AND MUST BE ORDERED IN ADDITION TO THE AIRBAG SWITCH KIT. THE NEW INSERT MUST BE PRESENTED TO THE CUSTOMER AFTER INSTALLATION.** Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 1165 Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 1166 Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 1167 Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 1168 Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 1169 PARTS REQUIRED: NOTE: SOME INSTRUCTION SHEETS FOR THE 1999 MODELS LIST ONLY 1998 MODELS ON THE COVER PAGE. THE 1998 KITS CAN BE USED ON ALL 1999 CARRY-OVER VEHICLES. DEACTIVATION/DOCUMENTATION PROCEDURE: 1. Before you install any airbag on-off switch for owners of air bag equipped vehicles, the owner must present to you an "Authorization Form" from the U.S. Department of Transportation National Highway Traffic Safety Administration (NHTSA), certifying the specific vehicle by its vehicle identification number. The authorization applies only to the vehicle identified and not to other vehicles that the owner may have~ 2. The owner must complete the "Authorization to Install Air Bag On-Off Switch Release Agreement Form" available in the "Forms Folder" under "TSB/Recall" tab of MDS2 and printed on your dealership letterhead. keep a copy for your records and make a copy for the vehicle owner. 3. Complete the NHTSA authorization form, and return it to NHTSA within seven days, making copies for the owner's and your records. NOTE: ALL DEALER OWNED USED VEHICLES SHOULD BE INSPECTED FOR PROPER AIRBAG OPERATION, i.e. NOT DEACTIVATED, PRIOR TO RESALE. POLICY: Information Only Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 1170 Air Bag Deactivation Switch: Technical Service Bulletins Air Bag System - ON-OFF Switch Availibility NO: 08-17-98 Rev. C GROUP: Electrical DATE: Dec. 30, 1998 SUBJECT: Airbag On-Off Switches THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-17-98 Rev. B DATED SEPTEMBER 18, 1998 WHICH SHOULD BE REMOVED FROM YOUR FILES. ADDITIONAL MODELS HAVE BEEN ADDED. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**. MODELS: **1990 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan** 1995 - **1999** (AB) Ram Van/Wagon **1990 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon** 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/Convertible 1994 -**1999** (AN) Dakota 1990 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1991 - 1995 (AS) Town & Country/Caravan/Voyager **1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue** 1994 - **1999** (BR) Ram Pickup **1995 - 1996 (B7) Stealth** 1998 - **1999** (DN) Durango **1995 - 1999 (FJ) Avenger/Sebring/Talon** 1995 - **1999** (JA) Breeze/Cirrus/Stratus 1996 - **1999** (JX) Sebring Convertible 1993 -**1999** (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - **1999** (NS) Town & Country/Caravan/ Voyager 1995 - **1999** (PL) Neon 1996 - 1997 (SR) Viper 1997 - **1999** (TJ) Wrangler 1997 - **1999** (XJ) Cherokee 1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer NOTE: THIS BULLETIN IS PROVIDED TO IDENTIFY THE PARTS AND PROCEDURES NECESSARY TO DEACTIVATE AIRBAGS AUTHORIZED BY NHTSA. AIRBAG DEACTIVATION IS A CUSTOMER PAY PROCEDURE, NOT COVERED UNDER THE PROVISIONS OF THE WARRANTY. THE COMPONENT PARTS ARE COVERED UNDER THE APPROPRIATE MOPAR PART WARRANTY. DISCUSSION: DaimlerChrysler Corporation is now offering airbag on-off switches for the selected vehicles listed above. Other applicable passenger vehicles will be announced as soon as the switches are available. The switches are packaged in a kit containing all necessary parts (except as indicated) and a detailed instruction sheet. Under the National Highway Traffic Safety Administration's rule, consumers will be authorized for on-off switches by claiming they meet any of several criteria. Airbag on-off switches must not be installed without the vehicle owner presenting the NHTSA authorization letter. For more information concerning the authorization process and/or the authorization letter call NHTSA's Auto Safety Hotline at 1-800-424-9393. We encourage you (dealer) to install these switches when the customer is interested in doing so and has the necessary NHTSA authorization. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 1171 Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 1172 Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 1173 Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 1174 PARTS REQUIRED: Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 1175 NOTE: SOME INSTRUCTION SHEETS FOR THE 1999 MODELS LIST ONLY 1998 MODELS ON THE COVER PAGE. THE 1998 KITS CAN BE USED ON ALL 1999 CARRY-OVER VEHICLES. DEACTIVATION/DOCUMENTATION PROCEDURE: 1. Before you install any airbag on-off switch for owners of air bag equipped vehicles, the owner must present to you an "Authorization Form" from the U.S. Department of Transportation National Highway Traffic Safety Administration (NHTSA), certifying the specific vehicle by its vehicle identification number. The authorization applies only to the vehicle identified and not to other vehicles that the owner may have. 2. The owner must complete the "Authorization to Install Air Bag On-Off Switch Release Agreement Form" available on T.I.L. and printed on your dealership letterhead. Keep a copy for your records and make a copy for the vehicle owner. 3. Complete the NHTSA authorization form, and return it to NHTSA within seven days, making copies for the owner's and your records. NOTE: ALL DEALER OWNED USED VEHICLES SHOULD BE INSPECTED FOR PROPER AIRBAG OPERATION, i.e. NOT DEACTIVATED, PRIOR TO RESALE. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 1176 POLICY: Information Only Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Page 1177 Air Bag Deactivation Switch: Specifications Tighten the three screws that secure the passenger side airbag on/off switch to the switch bezel to 2.2 Nm (20 in lbs). Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Page 1178 Passenger Side Airbag On/Off Switch Remove/Install Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Page 1179 Air Bag Deactivation Switch: Diagrams Passenger Airbag On/Off Switch C1 - 2 Way Passenger Airbag On/Off Switch C2 - 4 Way Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Page 1180 Air Bag Deactivation Switch: Service Precautions WARNING: THE KEY MUST ALWAYS BE REMOVED FROM THE PASSENGER SIDE AIRBAG ON/OFF SWITCH KEY ACTUATOR AFTER THE SWITCH HAS BEEN USED. NEVER LEAVE A KEY IN THE SWITCH KEY ACTUATOR. FAILURE TO OBSERVE THIS WARNING COULD RESULT IN ACCIDENTAL, INCOMPLETE OR IMPROPER AIRBAG DEPLOYMENT AND POSSIBLE OCCUPANT INJURIES . Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Page 1181 Air Bag Deactivation Switch: Description and Operation PASSENGER AIRBAG ON/OFF SWITCH A Passenger Airbag On/Off Switch located on the instrument panel allows the passenger airbag module to be turned OFF when certain child restraint devices are being used in the right front seating position. The switch is equipped with a key cylinder so that the switch position can only be changed using an ignition key. When the ignition switch is in the On position and the passenger side airbag is OFF, a Light-Emitting Diode (LED) illuminates an "OFF" indicator lamp on the faceplate of the switch. The passenger side airbag ON/OFF switch is located on the instrument panel. To turn OFF the passenger side airbag, turn the key actuator switch from the vertical position to a slanted position (pointing to the "OFF" light indicator), approximately 45 degrees clockwise, remove the key completely from the switch and verify that the switch actuator hole stays in the new position (45 degrees clockwise from vertical). The switch is spring loaded to the "ON" position. It will return to the "ON" position unless you remove the key. When the IGNITION is ON, this procedure will illuminate the "OFF" light indicator on the passenger airbag ON/OFF switch. To re-enable the passenger side airbag, reverse the procedure above so that the key switch actuator is returned to a vertical position. NOTE: Do not turn ignition ON with key in Switch. Do not turn switch with ignition ON. Do not leave key in switch. Do not leave the key in the key actuator under any condition. WARNING: THE KEY MUST ALWAYS BE REMOVED FROM THE PASSENGER SIDE AIRBAG ON/OFF SWITCH KEY ACTUATOR AFTER THE SWITCH HAS BEEN USED. NEVER LEAVE A KEY IN THE SWITCH KEY ACTUATOR. FAILURE TO OBSERVE THIS WARNING COULD RESULT IN ACCIDENTAL, INCOMPLETE OR IMPROPER AIRBAG DEPLOYMENT AND POSSIBLE OCCUPANT INJURIES. The Passenger Airbag On/Off Switch cannot be adjusted or repaired and, if faulty or damaged, the switch must be replaced THE AIRBAG MODULE INFLATOR ASSEMBLY CONTAINS SODIUM AZIDE AND POTASSIUM NITRATE. THESE MATERIALS ARE POISONOUS AND EXTREMELY FLAMMABLE. CONTACT WITH ACID, WATER, OR HEAVY METALS MAY PRODUCE HARMFUL AND IRRITATING GASES (SODIUM HYDROXIDE IS FORMED IN THE PRESENCE OF MOISTURE) OR COMBUSTIBLE COMPOUNDS. IN ADDITION, THE PASSENGER AIRBAG MODULE CONTAINS ARGON GAS PRESSURIZED TO OVER 2500 PSI. DO NOT ATTEMPT TO DISMANTLE AN AIRBAG MODULE OR TAMPER WITH ITS INFLATOR. DO NOT PUNCTURE, INCINERATE, OR BRING INTO CONTACT WITH ELECTRICITY DO NOT STORE AT TEMPERATURE EXCEEDING 93°C (200°F). REPLACE AIRBAG SYSTEM COMPONENTS ONLY WITH PARTS SPECIFIED IN THE CHRYSLER MOPAR PARTS CATALOG. SUBSTITUTE PARTS MAY APPEAR INTERCHANGEABLE, BUT INTERNAL DIFFERENCES MAY RESULT IN INFERIOR OCCUPANT PROTECTION. THE FASTENERS, SCREWS, AND BOLTS ORIGINALLY USED FOR THE AIRBAG SYSTEM COMPONENTS HAVE SPECIAL COATINGS AND ARE SPECIFICALLY DESIGNED FOR THE AIRBAG BAG SYSTEM. THEY MUST NEVER BE REPLACED WITH ANY SUBSTITUTES. ANY TIME A NEW FASTENER IS NEEDED, REPLACE IT WITH THE CORRECT FASTENERS PROVIDED IN HE SERVICE PACKAGE OR SPECIFIED IN THE CHRYSLER MOPAR PARTS CATALOG. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Page 1182 Air Bag Deactivation Switch: Service and Repair WARNING: THE AIRBAG SYSTEM IS A SENSITIVE, COMPLEX ELECTROMECHANICAL UNIT. BEFORE ATTEMPTING TO DIAGNOSE OR SERVICE ANY AIRBAG SYSTEM OR RELATED STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENTS YOU MUST FIRST DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE. THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE FURTHER SYSTEM SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO DO THIS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. REMOVAL 1. Disconnect and isolate the battery negative cable. If either of the airbags has not been deployed, wait two minutes for the system capacitor to discharge before further service. 2. Remove the cluster bezel from the instrument panel. Refer to Cluster Bezel in the Replacement of Instrument Panel Systems for the procedures. 3. Remove the glove box from the instrument panel. Refer to Glove Box in the Replacement of Instrument Panel Systems for the procedures. Passenger Side Airbag On/Off Switch Wire Harness Connectors 4. Reach through the glove box opening to access and disconnect the two passenger side airbag on/off switch wire harness connectors from the instrument panel wire harness. These connectors are retained on a bracket located on the inboard glove box opening reinforcement. Passenger Side Airbag On/Off Switch Bezel Remove/Install 5. Remove the three screws that secure the passenger side airbag on/off switch bezel to the instrument panel. 6. Remove the passenger side airbag on/off switch and switch bezel from the instrument panel as a unit. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Page 1183 Passenger Side Airbag On/Off Switch Remove/Install 7. Remove the three screws that secure the passenger side airbag on/off switch to the back of the switch bezel. 8. Remove the passenger side airbag on/off switch from the switch bezel. INSTALLATION 1. Position the passenger side airbag on/off switch to the back of the switch bezel. 2. Install and tighten the three screws that secure the passenger side airbag on/off switch to the switch bezel. Tighten the screws to 2.2 Nm (20 in lbs) . 3. Route the passenger side airbag on/off switch wire harness through the switch bezel opening of the instrument panel. 4. Reach through the glove box opening to access and reconnect the two passenger side airbag on/off switch wire harness connectors to the instrument panel wire harness. These connectors are retained on a bracket located on the inboard glove box opening reinforcement. Be certain that both connectors are fully engaged and latched. 5. Position the passenger side airbag on/off switch bezel to the opening in the instrument panel. 6. Install and tighten the three screws that secure the passenger side airbag on/off switch bezel to the instrument panel. Tighten the screws to 2.2 Nm (20 in lbs). 7. Install the glove box onto the instrument panel. Refer to Glove Box in the Replacement of Instrument Panel Systems for the procedures. 8. Install the cluster bezel onto the instrument panel. Refer to Cluster Bezel in the Replacement of Instrument Panel Systems for the procedures. 9. Do not reconnect the battery negative cable at this time. Refer to Airbag System in the Diagnosis and Testing for the proper procedures. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations Impact Sensor: Locations Airbag Control Module The airbag impact and safing sensors are located inside the airbag control module. The airbag control module is located under the center of the instrument panel and is attached to the center instrument panel support bracket. The airbag impact and safing sensors are integral to the airbag control module and are not separately serviceable. If found to be defective, the airbag control module must be replaced as a whole unit. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Page 1187 Impact Sensor: Description and Operation Impact and Safing Sensors One electronic impact sensor is used in this airbag system. The impact sensor is an accelerometer that senses the rate of vehicle deceleration, which provides verification of the direction and severity of an impact. The impact sensor is calibrated for the specific vehicle, and is only serviced as a unit with the ACM. A pre-programmed decision algorithm in the ACM microprocessor determines when the deceleration rate as signaled by the impact sensor indicates an impact that is severe enough to require airbag system protection. When the programmed conditions are met, the ACM sends an electrical signal to deploy the airbags. In addition to the electronic impact sensor, there is an electromechanical sensor within the ACM called a safing sensor. The safing sensor is a normally open series switch located in the airbag deployment circuit of the ACM. This sensor detects impact energy of a lesser magnitude than the electronic impact sensor, and must be closed in order for the airbags to deploy. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Page 1188 Impact Sensor: Service and Repair The impact and safing sensors are integral to the airbag control module and are not separately serviceable. If the sensors or airbag control module is found to be defective, the airbag control module must be replaced as a complete unit. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Diagrams Seat Belt Buckle Switch: Diagrams Seatbelt Switch (Club Cab) - Green 2 Way Seatbelt Switch (Standard Cab) - Black 2 Way Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Locations Battery Temperature Sensor: Locations Battery Temperature Sensor Location The sensor is located under the battery and is attached (snapped into) the battery tray. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Locations > Page 1196 Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Locations > Page 1197 Battery Temperature Sensor: Service Precautions WARNING: TO PROTECT THE HANDS FROM BATTERY ACID, A SUITABLE PAIR OF HEAVY DUTY RUBBER GLOVES, NOT THE HOUSEHOLD TYPE, SHOULD BE WORN WHEN REMOVING OR SERVICING A BATTERY. SAFETY GLASSES ALSO SHOULD BE WORN . Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Locations > Page 1198 Battery Temperature Sensor: Description and Operation SYSTEM OPERATION The battery temperature sensor is used to determine the battery temperature and control battery charging rate. This temperature data, along with data from monitored line voltage, is used by the PCM to vary the battery charging rate. System voltage will be higher at colder temperatures and is gradually reduced at warmer temperatures. BATTERY TEMPERATURE SENSOR-PCM INPUT Provides a signal to the PCM corresponding to the battery temperature. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Testing and Inspection > Testing Battery Temperature Sensor: Testing and Inspection Testing To perform a complete test of this sensor and its circuitry, refer to the appropriate Powertrain Diagnostic Procedures. To test the sensor only, refer to the following: Battery Temperature Sensor Location 1. The sensor is located on the driver's side of the vehicle under the battery and is attached to (snapped into) the battery tray. Only one sensor is used, including vehicles with dual batteries (diesel engines). A two-wire pigtail harness is attached directly to the sensor. The opposite end of this harness connects the sensor to the engine wiring harness. 2. Disconnect the two-wire pigtail harness from the engine harness. 3. Attach ohmmeter leads to the wire terminals of the pigtail harness. 4. At room temperature of 25° C (75-80° F), an ohmmeter reading of 9,000 (9K) to 11,000 (11K) ohms should be observed. 5. If reading is above or below the specification, replace the sensor. 6. Refer to the Replacement for procedures. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Testing and Inspection > Page 1201 Battery Temperature Sensor: Service and Repair Battery Temperature Sensor Location The battery temperature sensor is located under the vehicle battery and is attached (snapped into) a mounting hole on battery tray. Only one sensor is used (dual batteries). The sensor is located under the battery on drivers side of vehicle. REMOVAL 1. Remove battery. Refer to Battery for procedures 2. Disconnect sensor pigtail harness from engine wire harness. 3. Pry sensor straight up from battery tray mounting hole. INSTALLATION 1. Feed pigtail harness through mounting hole in top of battery tray and press sensor into top of tray (snaps in). 2. Connect pigtail harness. 3. Install battery. Refer to Battery for procedures. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Locations Ignition Switch Lock Cylinder: Locations The Key-In-Switch is located in the ignition switch module. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Locations > Page 1206 Ignition Switch Lock Cylinder: Description and Operation IGNITION SWITCH AND KEY LOCK CYLINDER The ignition switch is located on the steering column. The Key-In-Switch is located in the ignition switch module. For removal/installation of either the key lock cylinder or ignition switch, refer to Ignition Switch and Key Cylinder Removal/Installation. On vehicles equipped with an automatic transmission and a steering column mounted shifter an interlock device is located within the steering column. This interlock device is used to lock the transmission shifter in the PARK position when the key is in the LOCKED or ACCESSORY position. The interlock device within the steering column is not serviceable. If repair is necessary, the steering column assembly must be replaced. On vehicles equipped with an automatic transmission and a floor mounted shifter, a cable connects the interlock device within the steering column assembly, to the transmission floor shift lever. This interlock device is used to lock the transmission shifter in the PARK position when the key is in the LOCKED or ACCESSORY position. The interlock device within the steering column is not serviceable. If repair is necessary, the steering column assembly must be replaced. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Locations > Page 1207 Ignition Switch Lock Cylinder: Service and Repair The ignition key must be in the key cylinder for cylinder removal. REMOVAL 1. Disconnect negative cable from battery. 2. If equipped with tilt column, remove tilt lever by turning it counterclockwise. Shroud Removal/Installation - Typical 3. Remove upper and lower covers (shrouds) from steering column. 4. If equipped with automatic transmission, place shifter in PARK position. Retaining Pin 5. A retaining pin is located at side of key cylinder assembly. a. Rotate key to RUN position. b. Press in on retaining pin while pulling key cylinder from ignition switch. INSTALLATION If installing ignition key lock cylinder only, proceed to following steps 2, 3 and 4. Also refer to following steps 12 through 18. If installing both switch and key cylinder, refer to steps 1 through 18. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Locations > Page 1208 Flag In RUN Position Key Cylinder Rear View 1. Rotate flag on rear of ignition switch until in RUN position. This step must be done to allow tang on key cylinder to fit into slots within ignition switch. Installing Key Cylinder Into Switch 2. With key into ignition key cylinder, rotate key clockwise until retaining pin can be depressed . Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Locations > Page 1209 3. Install key cylinder into ignition switch by aligning retaining pin into retaining pin slot. Push key cylinder into switch until retaining pin engages. After pin engages, rotate key to OFF or LOCK position. 4. Check for proper retention of key cylinder by attempting to pull cylinder from switch. Ignition Switch View From Column Park Lock Linkage - Automatic Transmission - Typical 5. Automatic Transmission Only: Before attaching ignition switch to steering column, the transmission shifter must be in PARK position. The park lock dowel pin on rear of ignition switch must also be properly indexed into the park lock linkage before installing switch. Steering Wheel Lock Lever Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Locations > Page 1210 6. The flag at rear of ignition switch must be properly indexed into steering column before installing switch. This flag is used to operate the steering wheel lock lever in steering column. This lever allows steering wheel position to be locked when key switch is in LOCK position. 7. Place ignition switch in LOCK position. The switch is in the LOCK position when column lock flag is parallel to ignition switch terminals. 8. Automatic Transmission Only: Apply a light coating of grease to park lock dowel pin and park lock slider linkage. Before installing switch, push the park lock slider linkage forward until it bottoms. Do a final positioning by pulling it rearward about one-quarter inch. 9. Apply a light coating of grease to both column lock flag and shaft at end of flag. 10. Place ignition switch into openings on steering column. a. Automatic Transmission Only: Be sure park lock dowel pin on rear of ignition switch enters slot in park lock slider linkage. b. Be sure flag on rear of switch is positioned above steering wheel lock lever. c. Align dowel pins on rear of switch into holes on side of steering column. d. Install 3 ignition switch mounting screws. Tighten screws to 3 Nm ± 0.5 Nm (26 in. lbs. ± 4 in. lbs.) torque. 11. Connect electrical connectors to ignition switch and halo lamp. Make sure that switch locking tabs are fully seated in wiring connectors. 12. Install steering column covers (shrouds). tighten screws to 2 Nm (17 in. lbs.) torque. 13. Install tilt column lever (if equipped). 14. Connect negative cable to battery. 15. Check for proper operation of halo light. 16. Automatic Transmission Only: Shifter should lock in PARK position when key is in LOCK position (if equipped with shift lock device). Shifter should unlock when key rotated to ON position. 17. Check for proper operation of ignition switch in ACCESSORY, LOCK, OFF; ON, RUN, and START positions. 18. Steering wheel should lock when key is in LOCK position. Rotate steering wheel to verify. Steering wheel should unlock when key is rotated to ON position. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Specifications Neutral Safety Switch: Specifications Switch, Park/Neutral 25 ft.lb Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Specifications > Page 1214 Solenoid Case Connector, Park/Neutral Position Switch Connector Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Specifications > Page 1215 Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Specifications > Page 1216 Neutral Safety Switch: Service and Repair Removal 1. Raise vehicle and position drain pan under switch. 2. Disconnect switch wires. 3. Remove switch from case. Installation Fig. 21 1. Move shift lever to Park and Neutral positions. Verify that switch operating lever fingers are centered in switch opening in case. 2. Install new seal on switch and install switch in case. Tighten switch to 34 Nm (26 ft. lbs.) torque. 3. Test continuity of new switch with 12V test lamp. 4. Connect switch wires and lower vehicle. 5. Top off transmission fluid level. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Description and Operation Overdrive Switch: Description and Operation The overdrive OFF (control) switch is located in the shift lever arm. The switch is a momentary contact device that signals the PCM to toggle current status of the overdrive function. At key-on, overdrive operation is allowed. Pressing the switch once causes the overdrive OFF mode to be entered and the overdrive OFF switch lamp to be illuminated. Pressing the switch a second time causes normal overdrive operation to be restored and the overdrive lamp to be turned off. The overdrive OFF mode defaults to ON after the ignition switch is cycled OFF and ON. The normal position for the control switch is the ON position. The switch must be in this position to energize the solenoid and allow a 3-4 upshift. The control switch indicator light illuminates only when the overdrive switch is turned to the OFF position, or when illuminated by the transmission control module. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 1225 Transmission Position Switch/Sensor: Service and Repair Park/Neutral Position Switch 1. Raise vehicle and position drain pan under switch. 2. Disconnect switch wires. 3. Remove switch from case. 4. Move shift lever to Park and Neutral positions. Verify that switch operating lever fingers are centered in switch opening in case. 5. Install new seal on switch and install switch in case. Tighten switch to 34 Nm (25 ft. lbs.) torque. 6. Test continuity of new switch with 12V test lamp. 7. Connect switch wires and lower vehicle. 8. Top off transmission fluid level. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations Output Shaft Speed Sensor, Transmission Solenoid 8-way Connector, Park/Neutral Switch Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Page 1229 Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Page 1230 Transmission Speed Sensor: Description and Operation Fig. 5 The speed sensor (Fig. 5) is located in the overdrive gear case. The sensor is positioned over the park gear and monitors transmission output shaft rotating speed. Speed sensor signals are triggered by the park gear lugs as they rotate past the sensor pickup face. Input signals from the sensor are sent to the transmission control module for processing. The vehicle speed sensor also serves as a backup for the transmission speed sensor. Signals from this sensor are shared with the powertrain control module. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations Transmission Temperature Sensor/Switch: Locations Governor Pressure Sensor, Transmission Temperature Sensor, Governor Pressure Solenoid, Governor The transmission temperature sensor is located in the transmission solenoid assembly in the valve body. The governor pressure sender and the transmission fluid temperature thermistor are separate sensors in the same component. This component is attached to the governor body in the solenoid assembly of the valve body. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations > Page 1234 Transmission Temperature Sensor/Switch: Description and Operation Transmission fluid temperature readings are supplied to the transmission control module by the thermistor. The temperature readings are used to control engagement of the fourth gear overdrive clutch, the converter clutch, and governor pressure. Normal resistance value for the thermistor at room temperature is approximately 1000 ohms. The PCM prevents engagement of the converter clutch and overdrive clutch, when fluid temperature is below approximately 10 °C (50 °F). If fluid temperature exceeds 126 °C (260 °F), the PCM causes a 4-3 downshift and engage the converter clutch. Engagement is according to the third gear converter clutch engagement schedule. The overdrive OFF lamp in the instrument panel illuminates when the shift back to third occurs. The transmission will not allow fourth gear operation until fluid temperature decreases to approximately 110 °C (230 °F). The thermistor is part of the governor pressure sensor assembly and is immersed in transmission fluid at all times. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four-Wheel Drive (4WD) Switch <--> [Four Wheel Drive Selector Switch] > Component Information > Locations 4WD Drive Switch Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four-Wheel Drive (4WD) Switch <--> [Four Wheel Drive Selector Switch] > Component Information > Diagrams > With Quad Cab Connector Pin Identification Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four-Wheel Drive (4WD) Switch <--> [Four Wheel Drive Selector Switch] > Component Information > Diagrams > With Quad Cab > Page 1241 Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Lockout Switch > Component Information > Diagrams > Diagram Information and Instructions Power Window Lockout Switch: Diagram Information and Instructions Introduction General Information (Part 1 Of 2) Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Lockout Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1247 General Information (Part 2 Of 2) Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Function Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Lockout Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1248 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Lockout Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1249 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Lockout Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1250 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Lockout Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1251 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Lockout Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1252 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Lockout Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1253 Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Lockout Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1254 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Lockout Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1255 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Lockout Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1256 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Lockout Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1257 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Lockout Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1258 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Terminal/Connector Repair-Thomas and Betts Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Lockout Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1259 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector. Removing Wire Terminal 4. Insert the probe end of Special Tool 6934 into the back of the connector cavity. 5. Grasp the wire and Special Tool 6934 and slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal. 7. Install the wire and terminal in the connector. Fully seat the terminal in the connector. Single Lock Tab 8. Push in the single lock tab on the side of the connector. Wiring Repair Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Lockout Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1260 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Lockout Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1261 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Lockout Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1262 Power Window Lockout Switch: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Lockout Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1263 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Lockout Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1264 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations Power Window And Lock Switch And Bezel Unit Remove/Install Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions Power Window Switch: Diagram Information and Instructions Introduction General Information (Part 1 Of 2) Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1270 General Information (Part 2 Of 2) Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Function Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1271 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1272 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1273 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1274 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1275 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1276 Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1277 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1278 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1279 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1280 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1281 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Terminal/Connector Repair-Thomas and Betts Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1282 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector. Removing Wire Terminal 4. Insert the probe end of Special Tool 6934 into the back of the connector cavity. 5. Grasp the wire and Special Tool 6934 and slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal. 7. Install the wire and terminal in the connector. Fully seat the terminal in the connector. Single Lock Tab 8. Push in the single lock tab on the side of the connector. Wiring Repair Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1283 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1284 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1285 Power Window Switch: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1286 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1287 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1288 Power Window Switch: Connector Views Driver Door Window/Lock Switch - 16 Way Passenger Door Window/Lock Switch Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Page 1289 Power Window Switch: Description and Operation SYSTEM OPERATION The power windows are controlled by two-way switches integral to the power window and lock switch and bezel unit on the trim panel of each front door. A second power window switch in the driver side switch and bezel unit allows the driver to control the passenger side window. A Light-Emitting Diode (LED) in the paddle of each switch is illuminated whenever the ignition switch is in the On position. The power window switch for the driver side front door has an Auto label on it. This switch has a second detent position beyond the normal Down position that provides an automatic one-touch window down feature. This feature is controlled by an electronic circuit and a relay that are integral to the driver side front door power window and lock switch unit. The power window switches control the battery and ground feeds to the power window motors. The passenger side power window switch receives a ground feed through the driver side power window switch for operating the passenger side power window motor. The power window and lock switch and bezel unit cannot be repaired and, if faulty or damaged, the entire switch and bezel unit must be replaced. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Page 1290 Power Window Switch: Testing and Inspection Power Window And Lock Switch And Bezel Unit Remove/Install The auto down feature of the driver side power window switch is controlled by an electronic circuit within the switch unit. The auto down circuitry is activated when the driver side power window switch is moved to the second detent in the Down direction. The outputs from the auto down circuitry are carried through the same switch pins that provide the normal down function. The auto down circuit cannot be tested. If the driver side power window switch continuity tests are passed, but the auto down feature is inoperative, replace the faulty driver side power window switch unit. The Light-Emitting Diode (LED) illumination lamps for all of the power window and lock switch and bezel unit switch paddles receive battery current through the power window circuit breaker in the junction block. If all of the LEDs are inoperative in either or both power window and lock switch and bezel units and the power windows are inoperative, perform the diagnosis for Power Window System. If the power windows operate, but any or all of the LEDs are inoperative, the power window and lock switch and bezel unit with the inoperative LED(s) is faulty and must be replaced. 1. Check the circuit breaker in the junction block. If OK, go to Step 2.If not OK, replace the faulty circuit breaker. 2. Turn the ignition switch to the On position. Check for battery voltage at the circuit breaker in the junction block. If OK, turn the ignition switch to the Off position and go to Step 3. If not OK, repair the circuit to the ignition switch as required. 3. Disconnect and isolate the battery negative cable. Remove the power window and lock switch and bezel unit from the door trim panel. Unplug the wire harness connector from the switch and bezel unit. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Page 1291 Power Window Switch Continuity - Driver Side Power Window Switch Continuity - Passenger Side 4. Test the power window switch continuity. See the Power Window Switch Continuity charts to determine if the continuity is correct in the Neutral, Up and Down switch positions. If OK, see Power Window Motor in the Diagnosis and Testing. If not OK, replace the faulty switch. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Page 1292 Power Window Switch: Service and Repair Power Window And Lock Switch And Bezel Unit Remove/Install REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Using a wide flat-bladed tool such as a trim stick, gently pry the upper edge of the switch bezel to release the retainer that secures the switch bezel to the door trim panel opening. 3. Pull the switch and bezel unit away from the door trim panel opening far enough to access and unplug the wire harness connector. 4. Remove the power window and lock switch and bezel unit from the door trim panel. 5. Reverse the removal procedures to install. When installing the switch and bezel unit to the door trim panel opening, insert the rear of the bezel into the opening, then push down on the front of the bezel until the retaining tab snaps into place. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations Washer Fluid Level Switch: Locations Washer Reservoir And Pump Remove/Install The washer fluid level sensor is mounted on the inboard side of the reservoir above the washer pump. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations > Page 1297 Washer Fluid Level Switch: Description and Operation SYSTEM OPERATION The washer fluid level sensor is mounted on the inboard side of the reservoir above the washer pump. A barbed nipple on the sensor is press-fit into a rubber grommet seal installed in a hole in the side of the reservoir. When the fluid level in the reservoir falls below the pivoting float on the sensor, the float changes position and closes the internal switch contacts of the sensor. Refer to Low Washer Fluid Warning Lamp in the Diagnosis and Testing for diagnosis of the low washer fluid warning lamp and circuit, including the sensor. The washer fluid level sensor cannot be repaired. If faulty or damaged, the sensor unit must be replaced. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations > Page 1298 Washer Fluid Level Switch: Service and Repair Washer Reservoir And Pump Remove/Install REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Unplug the wire harness connector from the washer pump. 3. Remove the washer supply hose from the washer pump and drain the washer fluid from the reservoir into a clean container for reuse. NOTE: The pivoting float of the washer fluid sensor must be in a horizontal position within the reservoir in order to be removed. With the reservoir empty and held in an upright position, the pivoting float will orient itself to the horizontal position when the sensor connector is pointed straight downwards. 4. Using a trim stick or another suitable wide flat-bladed tool, gently pry the washer fluid level sensor out of the rubber grommet seal. Care must be taken not to damage the reservoir. 5. Remove the rubber grommet seal from the reservoir and discard. 6. Reverse the removal procedures to install. Always use a new rubber grommet seal on the reservoir. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Specifications Windshield Washer Switch: Specifications Tighten the fasteners as follows: - Multi-function switch wire harness connector screw - 2 Nm (17 in lbs). - Multi-function switch mounting screws - 2 Nm (17 in lbs). Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Specifications > Page 1302 Windshield Washer Switch: Locations Multi-Function Switch The windshield wiper and washer switches are contained in the multi-function switch assembly. The multi-function switch assembly is secured to the left side of the steering column. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Diagram Information and Instructions Windshield Washer Switch: Diagram Information and Instructions Introduction General Information (Part 1 Of 2) Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1305 General Information (Part 2 Of 2) Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Function Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1306 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1307 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1308 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1309 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1310 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1311 Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1312 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1313 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1314 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1315 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1316 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Terminal/Connector Repair-Thomas and Betts Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1317 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector. Removing Wire Terminal 4. Insert the probe end of Special Tool 6934 into the back of the connector cavity. 5. Grasp the wire and Special Tool 6934 and slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal. 7. Install the wire and terminal in the connector. Fully seat the terminal in the connector. Single Lock Tab 8. Push in the single lock tab on the side of the connector. Wiring Repair Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1318 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1319 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1320 Windshield Washer Switch: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1321 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1322 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1323 Multi-Function Switch - 24 Way Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Page 1324 Windshield Washer Switch: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AN AIRBAG, REFER TO AIR BAGS AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY . Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Page 1325 Windshield Washer Switch: Description and Operation Multi-Function Switch SYSTEM OPERATION The windshield wiper and washer switches are contained in the multi-function switch assembly. The multi-function switch assembly is secured to the left side of the steering column. A knob on the end of the multi-function switch stalk is rotated to select the desired wiper speed or intermittent wipe delay, or depressed toward the steering column to activate the washer system. The multi-function switch contains circuitry for the following functions: Turn signals - Hazard warning - Headlamp beam selection A - Headlamp optical horn - Windshield wipers - Windshield washers. However, the multi-function switch cannot be repaired. If any function of the multi-function switch is faulty, or if the switch is damaged, the entire switch assembly must be replaced. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Page 1326 Windshield Washer Switch: Testing and Inspection Multi-Function Switch Continuity See System Diagnosis before testing the multi-function switch. For additional testing and inspection information please refer to Powertrain Management/Computers and Control Systems/ See: Body and Frame/Body Control Systems/Central Timer Module WARNING: ON VEHICLES EQUIPPED WITH AN AIRBAG, REFER TO AIR BAGS AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. Unplug the multi-function switch wire harness connector from the multi-function switch. 3. Using an ohmmeter, perform the switch continuity checks at the switch terminals as shown in the Multi-Function Switch Continuity chart. 4. If the switch fails any of the continuity checks, replace the faulty switch. If the switch is OK, repair the wiper system and/or washer system wire harness circuits as required. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Page 1327 Windshield Washer Switch: Service and Repair REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIR BAGS AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. If the vehicle is so equipped remove the tilt steering column lever. 3. Remove both the upper and lower shrouds from the steering column. 4. Remove the lower fixed column shroud. Multifunction Switch 5. Move the upper fixed column shroud far enough to access the rear of the multi-function switch. 6. Remove the tamper proof mounting screws (a Snap On tamper proof Torx bit TTXR20B2 or equivalent is required) that secure the multi-function switch to the steering column. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Page 1328 7. Gently pull the switch away from the steering column far enough to access and remove the multi-function switch wire harness connector screw. 8. Unplug the wire harness connector from the multi-function switch. 9. Reverse the removal procedures to install. Tighten the fasteners as follows: - Multi-function switch wire harness connector screw - 2 Nm (17 in lbs). - Multi-function switch mounting screws - 2 Nm (17 in lbs). Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Specifications Wiper Switch: Specifications Tighten the fasteners as follows: - Multi-function switch wire harness connector screw - 2 Nm (17 in lbs). - Multi-function switch mounting screws - 2 Nm (17 in lbs). Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Specifications > Page 1332 Wiper Switch: Locations Multi-Function Switch The windshield wiper and washer switches are contained in the multi-function switch assembly. The multi-function switch assembly is secured to the left side of the steering column. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Diagram Information and Instructions Wiper Switch: Diagram Information and Instructions Introduction General Information (Part 1 Of 2) Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1335 General Information (Part 2 Of 2) Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Function Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1336 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1337 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1338 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1339 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1340 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1341 Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1342 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1343 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1344 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1345 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1346 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Terminal/Connector Repair-Thomas and Betts Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1347 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector. Removing Wire Terminal 4. Insert the probe end of Special Tool 6934 into the back of the connector cavity. 5. Grasp the wire and Special Tool 6934 and slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal. 7. Install the wire and terminal in the connector. Fully seat the terminal in the connector. Single Lock Tab 8. Push in the single lock tab on the side of the connector. Wiring Repair Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1348 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1349 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1350 Wiper Switch: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1351 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1352 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1353 Multi-Function Switch - 24 Way Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Page 1354 Wiper Switch: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AN AIRBAG, REFER TO AIR BAGS AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY . Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Page 1355 Wiper Switch: Description and Operation Multi-Function Switch SYSTEM OPERATION The windshield wiper and washer switches are contained in the multi-function switch assembly. The multi-function switch assembly is secured to the left side of the steering column. A knob on the end of the multi-function switch stalk is rotated to select the desired wiper speed or intermittent wipe delay, or depressed toward the steering column to activate the washer system. The multi-function switch contains circuitry for the following functions: Turn signals - Hazard warning - Headlamp beam selection A - Headlamp optical horn - Windshield wipers - Windshield washers. However, the multi-function switch cannot be repaired. If any function of the multi-function switch is faulty, or if the switch is damaged, the entire switch assembly must be replaced. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Page 1356 Wiper Switch: Testing and Inspection For additional testing and inspection information please refer to Powertrain Management/Computers and Control Systems/ See: Body and Frame/Body Control Systems/Central Timer Module See Wiper System and/or Washer System Testing and Inspection before testing the multi-function switch. See: Wiper and Washer Systems/Testing and Inspection WARNING: ON VEHICLES EQUIPPED WITH AN AIRBAG, REFER TO AIR BAGS AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. Unplug the multi-function switch wire harness connector from the multi-function switch. Multi-Function Switch Continuity 3. Using an ohmmeter, perform the switch continuity checks at the switch terminals as shown in the Multi-Function Switch Continuity chart. 4. If the switch fails any of the continuity checks, replace the faulty switch. If the switch is OK, repair the wiper system and/or washer system wire harness circuits as required. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Page 1357 Wiper Switch: Service and Repair REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIR BAGS AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. If the vehicle is so equipped remove the tilt steering column lever. 3. Remove both the upper and lower shrouds from the steering column. 4. Remove the lower fixed column shroud. Multifunction Switch 5. Move the upper fixed column shroud far enough to access the rear of the multi-function switch. 6. Remove the tamper proof mounting screws (a Snap On tamper proof torx bit TTXR20B2 or equivalent is required) that secure the multi-function switch to the steering column. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Page 1358 7. Gently pull the switch away from the steering column far enough to access and remove the multi-function switch wire harness connector screw. 8. Unplug the wire harness connector from the multi-function switch. 9. Reverse the removal procedures to install. Tighten the fasteners as follows: - Multi-function switch wire harness connector screw - 2 Nm (17 in lbs). - Multi-function switch mounting screws - 2 Nm (17 in lbs). Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Pick-Up Alignment: Specifications Pick-Up CASTER: With a GVW of 8,800 lbs. and a Wheel Base of 134.7 inches: Preferred ........................................... .............................................................................................................................................................. ......... +3.10° Range ............................................................................................................................ .......................................................................................... ± 1.00° With a GVW of 8,800 lbs. and a Wheel Base of 138.7 inches: Preferred ........................................... .............................................................................................................................................................. ......... +3.15° Range ............................................................................................................................ .......................................................................................... ± 1.00° With a GVW of 8,800 lbs. and a Wheel Base of 154.7 inches: Preferred ........................................... .............................................................................................................................................................. ......... +3.25° Range ............................................................................................................................ .......................................................................................... ± 1.00° CAMBER: Not Set TOTAL TOE-IN: Preferred .............................................................................................................................................. .................................................................... +0.10° Range ................................................................. ..................................................................................................................................................... ± 0.10° CROSS CASTER: Preferred .............................................................................................................................................. ........................................................................... 0° Range ................................................................. ....................................................................................................................................................... ± 0.5° CROSS CAMBER: Not Set THRUST ANGLE: Preferred .............................................................................................................................................. ........................................................................... 0° Range ................................................................. ....................................................................................................................................................... ± 0.4° Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Pick-Up > Page 1364 Alignment: Specifications Cab-Chassis NOTE: To determine correct caster alignment angle for Cab-Chassis vehicles the following procedure must be performed. CASTER: Chassis Measurement 1. Take a height measurement to the center of the front gauge hole in the frame. Take another measurement to the center of the rear spring hanger bolt. Take these measurements on both sides of the vehicle. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Pick-Up > Page 1365 Corrected Caster Chart Cab-Chassis 2. Subtract the front measurement from the rear measurement and use the average between the right and left side. Use this number (caster correlation value) with the corrected caster chart to obtain the preferred caster angle. CAMBER: Not Set TOTAL TOE-IN: Preferred .............................................................................................................................................. .................................................................... +0.10° Range ................................................................. ..................................................................................................................................................... ± 0.10° CROSS CASTER: Preferred .............................................................................................................................................. ........................................................................... 0° Range ................................................................. ....................................................................................................................................................... ± 0.5° CROSS CAMBER: Not Set THRUST ANGLE: Preferred .............................................................................................................................................. ........................................................................... 0° Range ................................................................. ....................................................................................................................................................... ± 0.4° Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Page 1366 Alignment: Description and Operation Alignment Angles - Independent Front Suspension Alignment Angels - Link/Coil Wheel alignment is the positioning of the wheels in relation to the vehicle. This is accomplished through suspension and steering linkage adjustments. An alignment is essential for efficient steering, good directional stability and to minimize tire wear. The most important measurements of an alignment are caster, camber and toe position. CASTER is the forward or rearward tilt of the steering knuckle from vertical. Tilting the top of the knuckle rearward provides positive caster. Tilting the top of the knuckle forward provides negative caster. Caster is a directional stability angle which enables the front wheels to return to a straight ahead position after turns. - CAMBER is the inward or outward tilt of the wheel relative to the center of the vehicle. Tilting the top of the wheel inward provides negative camber. Tilting the top of the wheel outward provides positive camber. Incorrect camber will cause wear on the inside or outside edge of the tire. - WHEEL TOE POSITION is the difference between the leading inside edges and trailing inside edges of the front tires. Incorrect wheel toe position is the most common cause of unstable steering and uneven tire wear. The wheel toe position is the final front wheel alignment adjustment. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Page 1367 CAUTION: Do not attempt to modify any suspension or steering components by heating and bending. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Page 1368 Alignment: Testing and Inspection PRE-ALIGNMENT Before starting wheel alignment, the following inspection and necessary corrections must be completed. 1. Inspect tires for size and tread wear. 2. Set tire air pressure. 3. Inspect front wheel bearings for wear. 4. Inspect front wheels for excessive radial or lateral runout and balance. 5. Inspect ball studs, linkage pivot points and steering gear for looseness, roughness or binding 6. Inspect suspension components for wear and noise. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Cab and Chassis Caster Correction Measurement Alignment: Service and Repair Cab and Chassis Caster Correction Measurement NOTE: To determine the correct caster alignment angle for Cab-Chassis vehicles the following procedure must be performed. - 4x2 11000 GVW has a solid front axle and uses a 4x4 frame. Corrected Caster Chart - Cab Chassis 1. Take a height measurement to the center of the front gauge hole in the frame. Take another measurement to the center of the rear spring hanger bolt. Take these measurements on both sides of the vehicle. 2. Subtract the front measurement from the rear measurement and use the average between the right and left side. Use this number (caster correlation valve) with the Corrected Caster Chart to obtain the preferred caster angle. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Cab and Chassis Caster Correction Measurement > Page 1371 Chassis Measurement Corrected Caster Chart-Cab Chassis Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Cab and Chassis Caster Correction Measurement > Page 1372 Alignment: Service and Repair Independent Front Suspension Before each alignment reading the vehicle should be jounced (rear first, then front). Grasp each bumper at the center and jounce the vehicle up and down several times. Always release the bumper in the down position. Set the front end alignment to specifications while the vehicle is in its NORMALLY LOADED CONDITION. Caster Camber Adjustment Location Camber and caster angle adjustments involve changing the position of the upper suspension arm pivot bar. CASTER: Move the rear position of the pivot bar in or out. This will change the caster angle significantly and camber angle only slightly. To retain camber move the forward pivot very slightly in the opposite direction. NOTE: For example, to increase a positive caster angle, move the rear position of the pivot bar inward (toward the engine). Move the front of pivot bar outward (away from the engine) slightly until the original camber angle is obtained. CAMBER: Move the forward position of the pivot bar in or out. This will change the camber angle significantly and caster angle only slightly. The camber angle should be adjusted as close as possible to the preferred service specification. After adjustment is made tighten pivot bar nuts to specifications. TOE POSITION: The wheel toe position adjustment should be the final adjustment. 1. Start the engine and turn wheels both ways before straightening the wheels. Center and secure the steering wheel and turn off engine. 2. Loosen the tie rod adjustment sleeve clamp bolts/nuts. NOTE: Each front wheel should be adjusted for one-half of the total toe position specification. This will ensure the steering wheel will be centered when the wheels are positioned straight-ahead. 3. Adjust the wheel toe position by turning the tie rod adjustment sleeves as necessary. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Cab and Chassis Caster Correction Measurement > Page 1373 Alignment: Service and Repair Link/Coil Suspension Before each alignment reading the vehicle should be jounced (rear first, then front). Grasp each bumper at the center and jounce the vehicle up and down several times. Always release the bumper in the down position. Set the front end alignment to specifications while the vehicle is in its NORMALLY LOADED CONDITION. CAMBER: The wheel camber angle is preset and is not adjustable. CASTER: Check the caster of the front axle for correct angle. Be sure the axle is not bent or twisted. Road test the vehicle and make left and right turn. Observe the steering wheel return-to-center position. Low caster will cause poor steering wheel returnability. Cam Adjuster Caster can be adjusted by rotating the cams on the lower suspension arm. TOE POSITION: The wheel toe position adjustment should be the final adjustment. 1. Start the engine and turn wheels both ways before straightening the wheels. Center and Secure the steering wheel and turn off engine. 2. Loosen the adjustment sleeve clamp bolts. Alignment Bar/Drag Link Adjustment CAUTION: Do not loosen/move alignment bar or alignment bar clamp. The bar is used as a locator for the adjuster clamps. 3. Adjust the right wheel toe position with the drag link. Turn the sleeve until the right wheel is at the correct TOE-IN position. Position clamp bolts to their original position and tighten to specifications. Make sure the toe setting does not change during clamp tightening. 4. Adjust left wheel toe position with tie rod at left knuckle. Turn the sleeve until the left wheel is at the correct TOE-IN position. Position clamp bolts to their original position and tighten to specifications. Make sure the toe setting does not change during clamp tightening. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Cab and Chassis Caster Correction Measurement > Page 1374 5. Verify the right toe setting. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Technical Service Bulletins > Engine - Low Power/Poor Performance Diagnosis Fuel Pressure: Technical Service Bulletins Engine - Low Power/Poor Performance Diagnosis NUMBER: 18-21-99 GROUP: Vehicle Performance DATE: Sep. 3, 1999 SUBJECT: 5.9L - 24V Cummins Diesel Low Power Or Poor Performance Diagnostic OVERVIEW: This bulletin involves diagnostic procedure that may be used to assist the technician in the diagnosis of a low power or poor performance complaint. MODELS: 1998 - 1999 (BR/BE) Ram Truck SYMPTOM/CONDITION: The vehicle operator may complain of slow acceleration or a lack of power when towing or hauling moderate to heavy loads. The condition may be worse at higher altitude. DIAGNOSIS: NOTE: DO NOT PROCEED WITH THIS TECHNICAL SERVICE BULLETIN (TSB) UNTIL TSB 18-11-99 HAS BEEN PERFORMED, ALL SCHEDULED MAINTENANCE OF THE AIR FILTER AND FUEL FILTER IS CURRENT, AND ANY ACTIVE OR INACTIVE DIAGNOSTIC TROUBLE CODES (DTC) HAVE BEEN REPAIRED. Interview the vehicle operator to understand under what driving conditions the above symptom occurs. 1). While inside the vehicle cab and using the Diagnostic Readout Box (DRB III(R)), verify that the throttle is opening fully. 2). Refer to the 1999 Ram Truck Service Manual 81-370-9108 pages 14-78 to 14-80. Perform the complete FUEL TRANSFER PUMP PRESSURE TEST procedure. 3). Inspect the fuel tank rollover valve for restrictions or that the shipping cap has not been left on the end of the valve. 4). Inspect the Charge Air Cooler hoses and clamps for proper installation. Inspect all connections and clamps for looseness. Verify that no leaks are present when the engine is under boost conditions. Pay close attention to the exhaust connections. 5). While performing the following road test, verify that the turbo boost pressure is 16 psi (33 in. of Hg.) during wide open throttle (WOT) acceleration. If boost pressure is found to be less than 16 psi (33 in. of Hg.), refer to TSB 11-08-98. 6). While road testing the vehicle in a safe area and manner, conduct an acceleration test. For vehicles equipped with an automatic transmission conduct a 0-60 mph acceleration test. For vehicles equipped with a manual transmission, conduct a 40-60 mph acceleration test in 4th gear. It may take the technician performing several acceleration tests to obtain consistent acceleration times. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Technical Service Bulletins > Engine - Low Power/Poor Performance Diagnosis > Page 1380 5.9L - 24V DIESEL 0-60 MPH WIDE OPEN THROTTLE ACCELERATION TEST 5.9L - 24V DIESEL 40-60 MPH WIDE OPEN THROTTLE ACCELERATION TEST IN 4th GEAR 7). Refer the to the acceleration reference charts. If the acceleration times, of the vehicle in question, are equal to or less than the stated times listed in the following acceleration charts, then the vehicle performance is normal and the vehicle can be returned to the vehicle owner. If the acceleration times are greater than the stated times listed in the acceleration charts, then further diagnostic testing is required. POLICY: Information Only Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Technical Service Bulletins > Page 1381 Fuel Pressure: Specifications Fuel Transfer (Lift) Pump Pressure Engine running .................................................................................................................................... .................................... 69 kPa (10 psi) Minimum Engine cranking ..................................................... .............................................................................................................. 48 kPa (5 - 7 psi) Minimum Fuel Injector "Pop Off" Pressure Using injector tester ............................................................................................................................................................. 31,026 kPa (4500 ± 250 psi) Fuel Injector Leak-Down Pressure ........................................................................................ Approximately 20 bars (291 psi) lower than pop pressure. Fuel Pressure Drop Across fuel filter test ports (at 2500 rpm)................................................................................................................................... 35 kPa (5 psi) maximum Overflow Valve Release Pressure At 2500 rpm ......................................................................................................................................... ..................................................... 97 kPa (14 psi) Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications > Diesel Idle Plate Idle Speed: Specifications Diesel Idle Plate ENGINE DATA PLATE The engine data plate contains: Advertised horsepower - Cubic inch/liter of engine - Engine model number - Fuel rate at advertised horsepower - Idle speed specification - Injection pump CPL number - Injection pump timing (in degrees) - Injector firing order - Valve lash specification Engine Data Plate Location If anything differs between the specifications found on the engine data plate and the specifications used in any service procedure, use specifications on data plate. The engine data plate is permanently riveted to the side of the engine timing gear cover located on the drivers side of engine. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications > Diesel Idle Plate > Page 1386 Idle Speed: Specifications Idle Speed Information Not Available Information not supplied by the manufacturer Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair Air Cleaner Fresh Air Duct/Hose: Service and Repair AIR INTAKE / BOOST SYSTEM The air intake system consists of the air cleaner/ housing assembly, turbocharger, charge air cooler piping, charge air cooler, intake air grid heater, and the intake manifold. Intake Air Circulation Intake air is drawn through the air cleaner and into the turbocharger compressor housing. Pressurized air from the turbocharger then flows forward through the charge air cooler located in front of the radiator. From the charge air cooler the air flows back into the intake manifold. The charge air cooler is a heat exchanger that uses air flow from vehicle motion to dissipate heat from the intake air. As the turbocharger increases air pressure, the air temperature increases. Lowering the intake air temperature increases engine efficiency and power. CAUTION: The charge air cooler must be cleaned following turbocharger failure involving an oil leak. Oil leaking from the turbocharger can cause engine runaway, possibly leading to engine failure. Refer to Charge Air Cooler Removal and Installation. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair Air Filter Element: Service and Repair Testing Air Cleaner Element Do not attempt to unnecessarily remove the top of the air cleaner housing for air cleaner element inspection on diesel engines. Filter Minder - Location The air cleaner (filter) housing is equipped with an air Filter Minder(R) gauge. This air flow restriction gauge will determine when the air cleaner element is restricted and should be replaced. Filter Minder The Filter Minded consists of a diaphragm and calibrated spring sealed inside of a plastic housing. A yellow colored disc attached to the diaphragm moves along a graduated scale on the side of the Filter Minder. After the engine has been shut off, a ratcheting device located within the Filter Minder will hold the yellow disc at the highest restriction that the air cleaner element has experienced. A drop in air pressure due to an air cleaner element restriction moves the diaphragm and the yellow disc will indicate the size of the air drop. CAUTION: Certain engine degreasers or cleaners may discolor or damage the plastic housing of the Filter Minder. Cover and tape the Filter Minder if any engine degreasers or cleaners are to be used. To test, turn the engine off. If the yellow disc has reached the red colored zone on the graduated scale, the air cleaner element should be replaced. Refer to the proceeding removal/installation paragraphs. Resetting the Filter Minder: After the air cleaner (filter) element has been replaced, press the rubber button on the top of the Filter Minder. This will allow the yellow colored disc to reset. After the button has been pressed, the yellow disc should spring back to the UP position. If the Filter Minder gauge has reached the red colored zone, and after an examination of the air cleaner (filter) element, the element appears to be clean, the high reading may be due to a temporary condition such as snow build-up at the air intake. Temporary high restrictions may also occur if the Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Page 1394 air cleaner (filter) element has gotten wet such as during a heavy rain or snow. If this occurs, allow the element to dry out during normal engine operation. Reset the rubber button on the top of the Filter Minder and retest after the element has dried. REMOVAL 1. Loosen air inlet tube clamp at air cleaner housing inlet. Remove this tube at air cleaner housing cover. 2. The housing cover is equipped with four (4) spring clips and is hinged at front with plastic tabs. Unlatch clips from top of air cleaner housing and tilt housing cover up and forward for cover removal. 3. Remove air cleaner element from air cleaner housing. INSTALLATION 1. Before installing a new air cleaner element, clean inside of air cleaner housing. 2. Position air cleaner cover to tabs on front of air cleaner housing. Latch four spring clips to seal cover to housing. 3. Install air inlet tube at air cleaner housing inlet. Note hose alignment notches at both inlet hose and air cleaner cover. 4. Position tube clamp to inlet tube and tighten to 3 Nm (25 in. lbs.) torque. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Specifications Fuel Filter: Specifications Fuel Drain Manifold "T" Fitting 12 Nm Fuel Filter Canister Mounting Nut 14 Nm Fuel Filter Drain Valve Mounting Screws 3-5 Nm Fuel Filter Canister Bracket Bolts 24 Nm Banjo Fittings at top of Filter/Separator 24 Nm Fuel Pump Module Locknut 24-44 Nm Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Specifications > Page 1398 Fuel Filter: Locations Fuel Filter/Water Separator Location The fuel filter/water separator assembly is located on left side of engine above starter motor. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Specifications > Page 1399 Fuel Filter: Description and Operation FUEL FILTER/WATER SEPARATOR The fuel filter/water separator protects the fuel injection pump by removing water and contaminants from the fuel. The construction of the filter/separator allows fuel to pass through it, but helps prevent moisture (water) from doing so. Moisture collects at the bottom of the canister. Fuel Filter/Water Separator Location The fuel filter/water separator assembly is located on left side of engine above starter motor. The assembly also includes the fuel heater and Water-In-Fuel (WIF) sensor. For draining of water from canister, refer to Fuel Filter/Water Separator Removal/Installation. A Water-In-Fuel (WIF) sensor is attached to side of canister. Refer to Water-In-Fuel Sensor Description/Operation. The fuel heater is installed into the top of the filter/separator housing. Refer to Fuel Heater Description/Operation. FUEL TANK MODULE An electric fuel pump is not used in the fuel tank module for diesel powered engines. Fuel is supplied by the engine mounted fuel transfer pump and the fuel injection pump. Top View Of Fuel Tank Module The fuel tank module is installed in the top of the fuel tank. The fuel tank module contains the following components: Fuel reservoir - A separate in-tank fuel filter - Rollover valve - Fuel gauge sending unit (fuel level sensor) - Fuel supply line connection - Fuel return line connection Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Specifications > Page 1400 - Auxiliary non-pressurized fuel supply fitting Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Service and Repair > Fuel Filter/Water Separator Replacement Fuel Filter: Service and Repair Fuel Filter/Water Separator Replacement Fuel Filter/Water Separator/Drain Hose Location The fuel filter/water separator assembly is located on left/rear side of engine above starter motor. The assembly contains the fuel filter cartridge, Water-In-Fuel (WIF) sensor, and fuel heater. REMOVAL Drain Valve At Fuel Filter/water Separator Draining water from filter canister: The canister drain valve serves two purposes. One is to partially drain filter canister of excess water. The other is to completely drain canister for filter, heater or water-in-fuel sensor replacement. The filter should be drained whenever water-in- fuel warning lamp remains illuminated. (Note that lamp will be illuminated for approximately two seconds when ignition key is initially placed in ON position for a bulb check). Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Service and Repair > Fuel Filter/Water Separator Replacement > Page 1403 Fuel Filter/water Separator Components 1. A drain hose is located at bottom of drain valve. Place drain pan under drain hose. 2. With engine not running, rotate drain valve handle forward to OPEN (DRAIN) position. Hold drain valve open until all water and contaminants have been removed and clean fuel exits drain hose. 3. If fuel filter, fuel heater or Water-In-Fuel (WIF) sensor is being replaced, drain canister completely. Dispose of mixture in drain pan according to applicable regulations. 4. After draining operation, rotate valve handle rearward to CLOSE position. If fuel filter, fuel heater or WIF sensor is being replaced, proceed to next step. 5. Remove drain hose at drain valve. 6. Disconnect Water-In-Fuel (WIF) sensor electrical connector at sensor. The WIF sensor is located at side of filter canister. 7. Loosen filter canister nut at top of header while lowering canister assembly from header. 8. Remove and discard seals and center O-rings . 9. Remove filter element (cartridge) from canister. 10. Remove WIF sensor and its O-ring seal from canister . 11. Inspect WIF sensor probes. Carefully clean contaminants from sensor probes with a cloth if necessary. Replace sensor if probes are covered with contaminants and will not clean up. Fuel Heater Mounting Screws (Bottom View) Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Service and Repair > Fuel Filter/Water Separator Replacement > Page 1404 12. Fuel Heater: The fuel heater is located inside fuel filter housing (header). The heater mounting plate, heating element, temperature sensor and wiring harness are serviced as one assembly. a. Disconnect heater pigtail harness electrical connector from main engine wiring harness near upper/rear of filter. b. The plastic electrical connector at end of 2-wire pigtail harness will have to be removed from wiring harness before attempting to pass harness through filter header. c. Note locations (colors) of wires in connector before removing connector. d. Remove clip retaining wires to connector. e. Remove wires from connector. f. Remove 3 fuel heater mounting screws. g. Press down on heater sealing grommet to remove heater from filter canister header. h. Pass wire harness through hole in filter header while removing heater from header. INSTALLATION 1. Clean inside of canister and canister header. 2. Fuel Heater: a. Lift fuel heater assembly into filter header while passing wire harness upward through hole in header. Heater sealing grommet should protrude at top of filter header. b. Instal 3 fuel heater mounting screws and tighten to 2-3 Nm (15-20 in. lbs.) torque. c. Install 2 wires into electrical connector and install connector clip. d. Connect heater pigtail harness electrical connector to main engine wiring harness. 3. Install new O-ring seal to WIF sensor. 4. Install WIF sensor to canister. tighten to 2-3 Nm (15-20 in. lbs.) torque. 5. If drain valve assembly is being replaced, tighten mounting screws to 3-5 Nm (30-40 in. lbs.) torque. 6. Install new O-rings. 7. Install new seal between canister and canister header. If filter canister is not filled with clean diesel fuel before installation, manual air bleeding of fuel system may be necessary (temporary rough engine running may occur). If necessary, refer to Air Bleed Procedures. 8. Load filter into canister. 9. Fill filter canister with clean diesel fuel. 10. Apply a light film of clean diesel oil to all seals. 11. Position canister assembly to canister header. Note locating tabs on canister should align into notch on canister header. 12. Install canister nut and tighten to 14 Nm (10 ft. lbs.) torque. 13. Connect electrical connector to WIF sensor. 14. Connect drain hose to bottom of drain valve. 15. Start engine and check for leaks. Air Bleed Procedure A certain amount of air becomes trapped in the fuel system when fuel system components on the supply and/or high-pressure side are serviced or replaced. Primary air bleeding is accomplished using the electric fuel transfer (lift) pump. If the vehicle has been allowed to run completely out of fuel, the fuel injectors must also be bled as the fuel injection pump is not self-bleeding (priming). Servicing or replacing components on the fuel return side will not require air bleeding. WARNING: DO NOT BLEED AIR FROM THE FUEL SYSTEM OF A HOT ENGINE. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Service and Repair > Fuel Filter/Water Separator Replacement > Page 1405 Fuel Supply Line Banjo Bolt 1. Loosen, but do not remove, banjo bolt holding low-pressure fuel supply line to side of fuel injection pump. Place a shop towel around banjo fitting to catch excess fuel. The fuel transfer (lift) pump is self-priming: When the key is first turned on (without cranking engine), the pump operates for approximately 2 seconds and then shuts off. The pump will also operate for up to 25 seconds after the starter is engaged, and then disengaged and the engine is not running. The pump shuts off immediately if the key is on and the engine stops running. 2. Turn key to CRANK position and quickly release key to ON position before engine starts. This will operate fuel transfer pump for approximately 25 seconds. 3. If fuel is not present at fuel supply line after 25 seconds, turn key OFF. Repeat previous step until fuel is exiting at fuel supply line. 4. tighten banjo bolt at fuel supply line to 24 Nm (18 ft. lbs.) torque. Primary air bleeding is now completed. 5. Attempt to start engine. If engine will not start, proceed to following steps. If engine does start, it may run erratically and be very noisy for a few minutes. This is a normal condition. 6. Continue to next step if: - The vehicle fuel tank has been allowed to run empty - The fuel injection pump has been replaced - High-pressure fuel lines have been replaced - Vehicle has not been operated after an extended period CAUTION: Do not engage the starter motor for more than 30 seconds at a time. Allow two minutes between cranking intervals. 7. Perform previous air bleeding procedure steps using fuel transfer pump. Be sure fuel is present at fuel supply line before proceeding. 8. Crank the engine for 30 seconds at a time to allow air trapped in the injection pump to vent out the drain manifold. WARNING: THE FUEL INJECTION PUMP SUPPLIES EXTREMELY HIGH FUEL PRESSURE TO EACH INDIVIDUAL INJECTOR THROUGH THE HIGH-PRESSURE LINES. FUEL UNDER THIS AMOUNT OF PRESSURE CAN PENETRATE THE SKIN AND CAUSE PERSONAL INJURY. WEAR SAFETY GOGGLES AND ADEQUATE PROTECTIVE CLOTHING AND AVOID CONTACT WITH FUEL SPRAY WHEN BLEEDING HIGH-PRESSURE FUEL LINES. ENGINE MAY START WHILE CRANKING STARTER MOTOR. 9. Engine may start, may run erratically and be very noisy for a few minutes. This is a normal condition. 10. Thoroughly clean area around injector fittings where they join injector connector tubes. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Service and Repair > Fuel Filter/Water Separator Replacement > Page 1406 Bleeding High-Pressure Fuel Lines At Injectors 11. Bleed air by loosening high-pressure fuel line fittings at cylinders number 3, 4 and 5. 12. Continue bleeding injectors until engine runs smoothly. It may take a few minutes for engine to run smooth. 13. Tighten fuel line(s) at injector(s) to 38 Nm (28 ft. lbs.) torque. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Service and Repair > Fuel Filter/Water Separator Replacement > Page 1407 Fuel Filter: Service and Repair Fuel Tank Module Replacement REMOVAL 1. Drain and remove fuel tank. Refer to Fuel Tank Removal/Installation. 2. Thoroughly clean area around tank module at top of tank. Locknut Removal/Installation - Typical Module 3. The plastic fuel tank module locknut is threaded onto fuel tank. Install Special Tool 6856 to locknut and remove locknut. The fuel tank module will spring up when locknut is removed. 4. Remove module from fuel tank. INSTALLATION CAUTION: Whenever the fuel tank module is serviced, the rubber gasket must be replaced. 1. Thoroughly clean locknut and locknut threads at top of tank. 2. Using new gasket, carefully position fuel tank module into opening in fuel tank. 3. Position locknut over top of fuel tank module. Install locknut finger tight. 4. When looking down at tank from drivers side of tank, the arrow at top of module should be aligned between two marks stamped into tank (approximately 2 o'clock position). The fuel line connectors, roll over valve and fuel gauge electrical connector should all be pointed to drivers side of vehicle. Rotate and align module/tank marks if necessary before tightening locknut. This step must be performed to prevent the module's float from contacting side of fuel tank. 5. Tighten locknut to 24-44 Nm (18-32 ft. lbs.) torque. 6. Install fuel tank. Refer to Fuel Tank Removal/ Installation. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications Firing Order: Specifications Firing Order The cylinders are numbered front to rear; 1 to 6. The firing order is 1-5-3-6-2-4. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Timing > Number One Cylinder > Component Information > Locations Number One Cylinder: Locations Firing Order The cylinders are numbered front to rear; 1 to 6. The firing order is 1-5-3-6-2-4. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications Valve Clearance: Specifications Intake ................................................................................................................................................... ............................................ 0.254 mm (0.010 inch) Exhaust ................................................................................................................................................ ............................................. 0.508 mm (0.020 inch) Note: Adjust valves when the engine is cold, below 60°C (140 °F). Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications > Page 1418 Valve Clearance: Adjustments VALVE LASH VERIFICATION & ADJUSTMENT NOTE: To obtain accurate readings, valve lash measurements AND adjustments should only be performed when the engine coolant temperature is less than 60° C (140° F). NOTE: The 24 valve overhead system is a "low-maintenance" design. Routine adjustments are no longer necessary, however, measurement should still take place when trouble-shooting performance problems, or upon completion of a repair that includes removal and installation of the valve train components. 1. Disconnect battery negative cables. Cylinder Head Cover And Gasket 2. Remove cylinder head cover. Fuel Pump Gear Access Cover 3. Remove the fuel pump gear access cover. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications > Page 1419 Fuel Pump Gear Timing Mark Orientation 4. Using the crankshaft barring tool # 7471B, rotate the engine and align the pump gear mark with the top dead center (TDC) mark on the gear housing cover. Measuring Valve Lash 5. With the engine in this position (pump gear mark at 12 o'clock), valve lash can be measured at the following rocker arms: INTAKE 1-2-4 / EXHAUST 1-3-5 Measure the valve lash by inserting a feeler gauge between the rocker arm socket and crosshead. Refer to the Valve Lash Limit Chart for the correct specifications. If the measurement falls within the limits, adjustment/resetting is not necessary. If measurement finds the lash outside of the limits, adjustment/resetting is required. VALVE LASH LIMIT CHART INTAKE MIN. ..................................................................................................................................................... ..................................... 0.152 mm (0.006 in.) MAX. ............................................................................ ............................................................................................................. 0.381 mm (0.015 in.) EXHAUST MIN. ..................................................................................................................................................... ..................................... 0.381 mm (0.015 in.) MAX. ............................................................................ ............................................................................................................. 0.762 mm (0.030 in.) NOTE: If measured valve lash falls within these specifications, no adjustment/reset is necessary. Engine operation within these ranges has no adverse affect on performance, emissions, fuel economy or level of engine noise. 6. If adjustment/resetting is required, loosen the lock nut on rocker arms and turn the adjusting screw until the desired lash is obtained: Adjust valves when the engine is cold, below 60°C (140°F) Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications > Page 1420 ^ INTAKE 0.254 mm (0.010 in.) ^ EXHAUST 0.508 mm (0.020 in.) 7. Tighten the lock nut and re-check the valve lash. Fuel Pump Gear Timing Mark Orientation 8. Using the crankshaft barring tool, rotate the crankshaft one revolution (360°) to align the pump gear mark to the 6 o'clock position in relation to the TDC mark on the gear housing cover 9. With the engine in this position (pump gear mark at 6 o'clock), valve lash can be measured at the remaining rocker arms: INTAKE 3-5-6 / EXHAUST 2-4-6. Use the same method as above for determining whether adjustment is necessary, and adjust those that are found to be outside of the limits. Cylinder Head Cover And Gasket 10. Install the cylinder head cover. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications > Page 1421 Fuel Pump Gear Access Cover 11. Install the fuel pump gear access cover. 12. Connect the battery negative cables. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Customer Interest: > 09-04-98 > Sep > 98 > Accessory Drive Belt - Noisy/Damaged Drive Belt: Customer Interest Accessory Drive Belt - Noisy/Damaged NO: 09-04-98 GROUP: Engine DATE: Sep. 25, 1998 SUBJECT: Accessory Drive Belt Noise Or Damage/Crank Pulley Bolt Loose MODELS: 1994 - 1999 (BR/BE) Ram Truck NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH AN 8.0L ENGINE. SYMPTOM/CONDITION: Some vehicles may exhibit a condition where the accessory drive belt becomes damaged on the inboard edge. Customers may explain the problem as belt noise. This may be caused by the crank pulley loosening on the crank and causing a misalignment. DIAGNOSIS: Inspect the accessory drive belt for fraying or unusual wear on the inboard edge. If wear is noted, inspect the crank pulley bolt for looseness and the crank pulley for misalignment. Sight the crank pulley with other accessory drives or use a straight edge to detect misalignment. If the crank pulley is misaligned or bolt is loose, perform the Repair Procedure. PARTS REQUIRED: 1 53041067 Belt, Accessory Drive 1994 - 1996 Models W/AC Federal 1 53041163 Belt, Accessory Drive 1994 - 1996 Models W/AC California 1 53041068 Belt, Accessory Drive 1994 - 1996 Models WO/AC Federal 1 53041164 Belt, Accessory Drive 1994 - 1996 Models WO/AC California 1 53041116 Belt, Accessory Drive 1997 - 1999 Models WO/AC Federal 1 53041117 Belt, Accessory Drive 1997 - 1999 Models WO/AC California 1 53041115 Belt, Accessory Drive 1997 - 1999 Models W/AC All 1 04318032 Adhesive, Stud and Bearing Mount REPAIR PROCEDURE: This bulletin involves removing the crank pulley bolt, checking the press fit of the pulley, reinstalling the bolt using thread locker, and replacing the accessory drive belt. 1. Disconnect the negative battery cable. 2. Remove the accessory drive belt following service manual procedures. 3. Drain and remove the radiator following all service manual warnings/cautions and procedures. NOTE: DRAIN THE COOLANT INTO A CLEAN DRAIN PAN. 4. Remove the bolt attaching the crankshaft pulley damper to the crankshaft. 5. Using your hands, pull on the crankshaft pulley damper to test the press fit to the crank shaft. The pulley should be tight and not come off the crank with hand pressure. NOTE: IF THE CRANK PULLEY DAMPER IS LOOSE (NO PRESS FIT) REPLACE THE CRANK PULLEY DAMPER WITH P/N 53020776. 6. Use Miller Tool C-3688 and fully press the crankshaft pulley damper onto the crankshaft. 7. Add thread locker p/n 04318032 to the end 3 or 4 threads of the crank pulley bolt. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Customer Interest: > 09-04-98 > Sep > 98 > Accessory Drive Belt - Noisy/Damaged > Page 1430 8. Install the bolt and torque it to 312 Nm (230 ft. lbs.). NOTE: USE A BAR TO LOCK THE PULLEY IN PLACE WHILE TIGHTENING. 9. Install a new accessory drive belt following service manual procedures. 10. Reinstall the radiator following service manual procedures. 11. Reinstall the negative battery cable. 12. Fill the cooling system with the saved coolant and operate the vehicle to purge air from the system. Top off the automatic transmission fluid (if required). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 09-25-25-90 1.5 Hrs. FAILURE CODE: P8 - New Part Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-04-98 > Sep > 98 > Accessory Drive Belt - Noisy/Damaged Drive Belt: All Technical Service Bulletins Accessory Drive Belt - Noisy/Damaged NO: 09-04-98 GROUP: Engine DATE: Sep. 25, 1998 SUBJECT: Accessory Drive Belt Noise Or Damage/Crank Pulley Bolt Loose MODELS: 1994 - 1999 (BR/BE) Ram Truck NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH AN 8.0L ENGINE. SYMPTOM/CONDITION: Some vehicles may exhibit a condition where the accessory drive belt becomes damaged on the inboard edge. Customers may explain the problem as belt noise. This may be caused by the crank pulley loosening on the crank and causing a misalignment. DIAGNOSIS: Inspect the accessory drive belt for fraying or unusual wear on the inboard edge. If wear is noted, inspect the crank pulley bolt for looseness and the crank pulley for misalignment. Sight the crank pulley with other accessory drives or use a straight edge to detect misalignment. If the crank pulley is misaligned or bolt is loose, perform the Repair Procedure. PARTS REQUIRED: 1 53041067 Belt, Accessory Drive 1994 - 1996 Models W/AC Federal 1 53041163 Belt, Accessory Drive 1994 - 1996 Models W/AC California 1 53041068 Belt, Accessory Drive 1994 - 1996 Models WO/AC Federal 1 53041164 Belt, Accessory Drive 1994 - 1996 Models WO/AC California 1 53041116 Belt, Accessory Drive 1997 - 1999 Models WO/AC Federal 1 53041117 Belt, Accessory Drive 1997 - 1999 Models WO/AC California 1 53041115 Belt, Accessory Drive 1997 - 1999 Models W/AC All 1 04318032 Adhesive, Stud and Bearing Mount REPAIR PROCEDURE: This bulletin involves removing the crank pulley bolt, checking the press fit of the pulley, reinstalling the bolt using thread locker, and replacing the accessory drive belt. 1. Disconnect the negative battery cable. 2. Remove the accessory drive belt following service manual procedures. 3. Drain and remove the radiator following all service manual warnings/cautions and procedures. NOTE: DRAIN THE COOLANT INTO A CLEAN DRAIN PAN. 4. Remove the bolt attaching the crankshaft pulley damper to the crankshaft. 5. Using your hands, pull on the crankshaft pulley damper to test the press fit to the crank shaft. The pulley should be tight and not come off the crank with hand pressure. NOTE: IF THE CRANK PULLEY DAMPER IS LOOSE (NO PRESS FIT) REPLACE THE CRANK PULLEY DAMPER WITH P/N 53020776. 6. Use Miller Tool C-3688 and fully press the crankshaft pulley damper onto the crankshaft. 7. Add thread locker p/n 04318032 to the end 3 or 4 threads of the crank pulley bolt. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-04-98 > Sep > 98 > Accessory Drive Belt - Noisy/Damaged > Page 1436 8. Install the bolt and torque it to 312 Nm (230 ft. lbs.). NOTE: USE A BAR TO LOCK THE PULLEY IN PLACE WHILE TIGHTENING. 9. Install a new accessory drive belt following service manual procedures. 10. Reinstall the radiator following service manual procedures. 11. Reinstall the negative battery cable. 12. Fill the cooling system with the saved coolant and operate the vehicle to purge air from the system. Top off the automatic transmission fluid (if required). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 09-25-25-90 1.5 Hrs. FAILURE CODE: P8 - New Part Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > All Other Service Bulletins for Drive Belt: > 08-32-99 > Oct > 99 > Two Way Radio - Intermittent Poor Reception Air Bag Control Module: All Technical Service Bulletins Two Way Radio - Intermittent Poor Reception NUMBER: 08-32-99 GROUP: Electrical DATE: Oct. 1, 1999 SUBJECT: Radio Interference To/From Two-Way Radio Receivers OVERVIEW: This bulletin involves installing a revised Airbag Control Module (ACM). MODELS: 1998 - 1999 (BR/BE) Ram Truck SYMPTOM/CONDITION: Customers may complain of intermittent poor reception on their two-way radios. NOTE: THIS CONDITION DOES NOT AFFECT THE OPERATION OF ANY AM OR FM BAND RADIO. DISCUSSION: Radio receivers from approximately 30 MHZ to 50 MHZ may be susceptible to Radio Frequency Interference (RFI) from the Airbag Control Module (ACM). The following services are within this band range of 30 MHZ to 50 MHZ: ^ Public Service Low Band VHF (30 - 50 MHZ) ^ Six Meter Amateur Radio Band (50 - 54 MHZ) DIAGNOSIS: NOTE: TECHNICAL SERVICE BULLETIN 08-06-99, DATED MARCH 5, 1999, ADDRESSES TWO-WAY RADIO INTERFERENCE FROM THE FUEL PUMP MODULE AND SHOULD BE PERFORMED PRIOR TO PERFORMING THIS TECHNICAL SERVICE BULLETIN. Turn the ignition key to the RUN position. Operate the two-way radio and monitor for RFI/static/poor reception. If RFI is present with the ignition key in the RUN position, perform the following Repair Procedure. NOTE: THE INTERFERENCE MAY BE INTERMITTENT. IF THE CONDITION IS NOT PRESENT DURING THE DIAGNOSIS, REPEAT THE DIAGNOSIS SEVERAL TIMES TO ATTEMPT TO RE-CREATE THE CONDITION. NOTE: IT IS IMPORTANT TO IDENTIFY WHICH COMPONENTS ARE EMITTING RFI. AFTER A REPAIR HAS BEEN MADE, PERFORM THE DIAGNOSIS AGAIN TO IDENTIFY IF ANY OTHER COMPONENT IS PRODUCING RFI. SOME VEHICLES MAY REQUIRE ADDITIONAL DIAGNOSIS. PARTS REQUIRED: 1 56043128AE Module, Airbag Control REPAIR PROCEDURE: THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. 1. Replace the ACM with p/n 56043128AE. Refer to the appropriate Ram Truck Service Manual, Group 8M, for information regarding Airbag Control Module Removal And Installation procedures. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > All Other Service Bulletins for Drive Belt: > 08-32-99 > Oct > 99 > Two Way Radio - Intermittent Poor Reception > Page 1442 POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-45-09-92 0.3 Hrs. FAILURE CODE: P8 - New Part Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > All Other Service Bulletins for Drive Belt: > 08-32-99 > Oct > 99 > Two Way Radio - Intermittent Poor Reception > Page 1448 POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-45-09-92 0.3 Hrs. FAILURE CODE: P8 - New Part Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Page 1449 Drive Belt: Description and Operation All vehicles are available with either a 3.9L V-6, a 5.2L V-8, two different 5.9L V-8 engines, an 8.0L V-10 or a 5.9L in-line 6 cylinder diesel engine. The accessory drive components are operated by a single, crankshaft driven, serpentine drive belt on all engines. An automatic belt tensioner is also used to maintain correct belt tension at all times. This is used on all engines. Refer to Drive Belt Tensioner. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Page 1450 Drive Belt: Testing and Inspection VISUAL DIAGNOSIS Belt Wear Patterns When diagnosing serpentine accessory drive belts, small cracks that run across the ribbed surface of the belt from rib to rib, are considered normal. These are not a reason to replace the belt. However, cracks running along a rib (not across) are not normal. Any belt with cracks running along a rib must be replaced. Also replace the belt if it has excessive wear, frayed cords or severe glazing. Refer to the Accessory Drive Belt Diagnosis charts for further belt diagnosis. NOISE DIAGNOSIS Noises generated by the accessory drive belt are most noticeable at idle. Before replacing a belt to resolve a noise condition, inspect all of the accessory drive pulleys for alignment, glazing, or excessive end play. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Page 1451 Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Page 1452 ACCESSORY DRIVE BELT DIAGNOSIS CHART Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Page 1453 Drive Belt: Service and Repair NOTE: The belt routing schematics are published from the latest information available at the time of publication. If anything differs between these schematics and the Belt Routing Label, use the schematics on Belt Routing Label. This label is located in the engine compartment. CAUTION: Do not attempt to check belt tension with a belt tension gauge on vehicles equipped with an automatic belt tensioner. REMOVAL Belt Tensioner-5.9L Diesel-Typical (non-A/C Shown) Drive belts on diesel engines are equipped with a spring loaded automatic belt tensioner. This belt tensioner will be used on all belt configurations, such as with or without air conditioning. For more information, refer to Drive Belt Tensioner. 1. A 3/8 inch square hole is provided in the automatic belt tensioner. Attach a 3/8 inch drive-long handle ratchet to this hole. 2. Rotate ratchet and tensioner assembly counterclockwise (as viewed from front) until tension has been relieved from belt. 3. Remove belt from water pump pulley first. 4. Remove belt from vehicle. INSTALLATION Belt Routing-5.9L Diesel Engine-With A/C Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Page 1454 Belt Routing-5.9L Diesel Engine-Without A/C CAUTION: When installing the accessory drive belt, the belt must be routed correctly. If not, engine may overheat due to water pump rotating in wrong direction. Refer to for correct engine belt routing. The correct belt with correct length must be used. 1. Position drive belt over all pulleys except water pump pulley. 2. Attach a 3/8 inch ratchet to tensioner. 3. Rotate ratchet and belt tensioner counterclockwise. Place belt over water pump pulley. Let tensioner rotate back into place. Remove ratchet. Be sure belt is properly seated on all pulleys. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair Air Cleaner Fresh Air Duct/Hose: Service and Repair AIR INTAKE / BOOST SYSTEM The air intake system consists of the air cleaner/ housing assembly, turbocharger, charge air cooler piping, charge air cooler, intake air grid heater, and the intake manifold. Intake Air Circulation Intake air is drawn through the air cleaner and into the turbocharger compressor housing. Pressurized air from the turbocharger then flows forward through the charge air cooler located in front of the radiator. From the charge air cooler the air flows back into the intake manifold. The charge air cooler is a heat exchanger that uses air flow from vehicle motion to dissipate heat from the intake air. As the turbocharger increases air pressure, the air temperature increases. Lowering the intake air temperature increases engine efficiency and power. CAUTION: The charge air cooler must be cleaned following turbocharger failure involving an oil leak. Oil leaking from the turbocharger can cause engine runaway, possibly leading to engine failure. Refer to Charge Air Cooler Removal and Installation. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair Air Filter Element: Service and Repair Testing Air Cleaner Element Do not attempt to unnecessarily remove the top of the air cleaner housing for air cleaner element inspection on diesel engines. Filter Minder - Location The air cleaner (filter) housing is equipped with an air Filter Minder(R) gauge. This air flow restriction gauge will determine when the air cleaner element is restricted and should be replaced. Filter Minder The Filter Minded consists of a diaphragm and calibrated spring sealed inside of a plastic housing. A yellow colored disc attached to the diaphragm moves along a graduated scale on the side of the Filter Minder. After the engine has been shut off, a ratcheting device located within the Filter Minder will hold the yellow disc at the highest restriction that the air cleaner element has experienced. A drop in air pressure due to an air cleaner element restriction moves the diaphragm and the yellow disc will indicate the size of the air drop. CAUTION: Certain engine degreasers or cleaners may discolor or damage the plastic housing of the Filter Minder. Cover and tape the Filter Minder if any engine degreasers or cleaners are to be used. To test, turn the engine off. If the yellow disc has reached the red colored zone on the graduated scale, the air cleaner element should be replaced. Refer to the proceeding removal/installation paragraphs. Resetting the Filter Minder: After the air cleaner (filter) element has been replaced, press the rubber button on the top of the Filter Minder. This will allow the yellow colored disc to reset. After the button has been pressed, the yellow disc should spring back to the UP position. If the Filter Minder gauge has reached the red colored zone, and after an examination of the air cleaner (filter) element, the element appears to be clean, the high reading may be due to a temporary condition such as snow build-up at the air intake. Temporary high restrictions may also occur if the Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Page 1463 air cleaner (filter) element has gotten wet such as during a heavy rain or snow. If this occurs, allow the element to dry out during normal engine operation. Reset the rubber button on the top of the Filter Minder and retest after the element has dried. REMOVAL 1. Loosen air inlet tube clamp at air cleaner housing inlet. Remove this tube at air cleaner housing cover. 2. The housing cover is equipped with four (4) spring clips and is hinged at front with plastic tabs. Unlatch clips from top of air cleaner housing and tilt housing cover up and forward for cover removal. 3. Remove air cleaner element from air cleaner housing. INSTALLATION 1. Before installing a new air cleaner element, clean inside of air cleaner housing. 2. Position air cleaner cover to tabs on front of air cleaner housing. Latch four spring clips to seal cover to housing. 3. Install air inlet tube at air cleaner housing inlet. Note hose alignment notches at both inlet hose and air cleaner cover. 4. Position tube clamp to inlet tube and tighten to 3 Nm (25 in. lbs.) torque. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Specifications Fluid Filter - A/T: Specifications Fluid Filter Screws 35 in.lb Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair > Fluid Level Check Fluid Filter - A/T: Service and Repair Fluid Level Check For Transmission Fluid Services, refer to Automatic Transmission/Transaxle, Service and Repair, Service Procedures. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair > Fluid Level Check > Page 1469 Fluid Filter - A/T: Service and Repair Fluid and Filter Replacement For Transmission Fluid Services, refer to Automatic Transmission/Transaxle, Service and Repair, Service Procedures. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair > Fluid Level Check > Page 1470 Fluid Filter - A/T: Service and Repair Transmission Fill Procedure For Transmission Fluid Services, refer to Automatic Transmission/Transaxle, Service and Repair, Service Procedures. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Maintenance > Filters > Fuel Filter > Component Information > Specifications Fuel Filter: Specifications Fuel Drain Manifold "T" Fitting 12 Nm Fuel Filter Canister Mounting Nut 14 Nm Fuel Filter Drain Valve Mounting Screws 3-5 Nm Fuel Filter Canister Bracket Bolts 24 Nm Banjo Fittings at top of Filter/Separator 24 Nm Fuel Pump Module Locknut 24-44 Nm Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Maintenance > Filters > Fuel Filter > Component Information > Specifications > Page 1474 Fuel Filter: Locations Fuel Filter/Water Separator Location The fuel filter/water separator assembly is located on left side of engine above starter motor. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Maintenance > Filters > Fuel Filter > Component Information > Specifications > Page 1475 Fuel Filter: Description and Operation FUEL FILTER/WATER SEPARATOR The fuel filter/water separator protects the fuel injection pump by removing water and contaminants from the fuel. The construction of the filter/separator allows fuel to pass through it, but helps prevent moisture (water) from doing so. Moisture collects at the bottom of the canister. Fuel Filter/Water Separator Location The fuel filter/water separator assembly is located on left side of engine above starter motor. The assembly also includes the fuel heater and Water-In-Fuel (WIF) sensor. For draining of water from canister, refer to Fuel Filter/Water Separator Removal/Installation. A Water-In-Fuel (WIF) sensor is attached to side of canister. Refer to Water-In-Fuel Sensor Description/Operation. The fuel heater is installed into the top of the filter/separator housing. Refer to Fuel Heater Description/Operation. FUEL TANK MODULE An electric fuel pump is not used in the fuel tank module for diesel powered engines. Fuel is supplied by the engine mounted fuel transfer pump and the fuel injection pump. Top View Of Fuel Tank Module The fuel tank module is installed in the top of the fuel tank. The fuel tank module contains the following components: Fuel reservoir - A separate in-tank fuel filter - Rollover valve - Fuel gauge sending unit (fuel level sensor) - Fuel supply line connection - Fuel return line connection Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Maintenance > Filters > Fuel Filter > Component Information > Specifications > Page 1476 - Auxiliary non-pressurized fuel supply fitting Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Maintenance > Filters > Fuel Filter > Component Information > Service and Repair > Fuel Filter/Water Separator Replacement Fuel Filter: Service and Repair Fuel Filter/Water Separator Replacement Fuel Filter/Water Separator/Drain Hose Location The fuel filter/water separator assembly is located on left/rear side of engine above starter motor. The assembly contains the fuel filter cartridge, Water-In-Fuel (WIF) sensor, and fuel heater. REMOVAL Drain Valve At Fuel Filter/water Separator Draining water from filter canister: The canister drain valve serves two purposes. One is to partially drain filter canister of excess water. The other is to completely drain canister for filter, heater or water-in-fuel sensor replacement. The filter should be drained whenever water-in- fuel warning lamp remains illuminated. (Note that lamp will be illuminated for approximately two seconds when ignition key is initially placed in ON position for a bulb check). Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Maintenance > Filters > Fuel Filter > Component Information > Service and Repair > Fuel Filter/Water Separator Replacement > Page 1479 Fuel Filter/water Separator Components 1. A drain hose is located at bottom of drain valve. Place drain pan under drain hose. 2. With engine not running, rotate drain valve handle forward to OPEN (DRAIN) position. Hold drain valve open until all water and contaminants have been removed and clean fuel exits drain hose. 3. If fuel filter, fuel heater or Water-In-Fuel (WIF) sensor is being replaced, drain canister completely. Dispose of mixture in drain pan according to applicable regulations. 4. After draining operation, rotate valve handle rearward to CLOSE position. If fuel filter, fuel heater or WIF sensor is being replaced, proceed to next step. 5. Remove drain hose at drain valve. 6. Disconnect Water-In-Fuel (WIF) sensor electrical connector at sensor. The WIF sensor is located at side of filter canister. 7. Loosen filter canister nut at top of header while lowering canister assembly from header. 8. Remove and discard seals and center O-rings . 9. Remove filter element (cartridge) from canister. 10. Remove WIF sensor and its O-ring seal from canister . 11. Inspect WIF sensor probes. Carefully clean contaminants from sensor probes with a cloth if necessary. Replace sensor if probes are covered with contaminants and will not clean up. Fuel Heater Mounting Screws (Bottom View) Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Maintenance > Filters > Fuel Filter > Component Information > Service and Repair > Fuel Filter/Water Separator Replacement > Page 1480 12. Fuel Heater: The fuel heater is located inside fuel filter housing (header). The heater mounting plate, heating element, temperature sensor and wiring harness are serviced as one assembly. a. Disconnect heater pigtail harness electrical connector from main engine wiring harness near upper/rear of filter. b. The plastic electrical connector at end of 2-wire pigtail harness will have to be removed from wiring harness before attempting to pass harness through filter header. c. Note locations (colors) of wires in connector before removing connector. d. Remove clip retaining wires to connector. e. Remove wires from connector. f. Remove 3 fuel heater mounting screws. g. Press down on heater sealing grommet to remove heater from filter canister header. h. Pass wire harness through hole in filter header while removing heater from header. INSTALLATION 1. Clean inside of canister and canister header. 2. Fuel Heater: a. Lift fuel heater assembly into filter header while passing wire harness upward through hole in header. Heater sealing grommet should protrude at top of filter header. b. Instal 3 fuel heater mounting screws and tighten to 2-3 Nm (15-20 in. lbs.) torque. c. Install 2 wires into electrical connector and install connector clip. d. Connect heater pigtail harness electrical connector to main engine wiring harness. 3. Install new O-ring seal to WIF sensor. 4. Install WIF sensor to canister. tighten to 2-3 Nm (15-20 in. lbs.) torque. 5. If drain valve assembly is being replaced, tighten mounting screws to 3-5 Nm (30-40 in. lbs.) torque. 6. Install new O-rings. 7. Install new seal between canister and canister header. If filter canister is not filled with clean diesel fuel before installation, manual air bleeding of fuel system may be necessary (temporary rough engine running may occur). If necessary, refer to Air Bleed Procedures. 8. Load filter into canister. 9. Fill filter canister with clean diesel fuel. 10. Apply a light film of clean diesel oil to all seals. 11. Position canister assembly to canister header. Note locating tabs on canister should align into notch on canister header. 12. Install canister nut and tighten to 14 Nm (10 ft. lbs.) torque. 13. Connect electrical connector to WIF sensor. 14. Connect drain hose to bottom of drain valve. 15. Start engine and check for leaks. Air Bleed Procedure A certain amount of air becomes trapped in the fuel system when fuel system components on the supply and/or high-pressure side are serviced or replaced. Primary air bleeding is accomplished using the electric fuel transfer (lift) pump. If the vehicle has been allowed to run completely out of fuel, the fuel injectors must also be bled as the fuel injection pump is not self-bleeding (priming). Servicing or replacing components on the fuel return side will not require air bleeding. WARNING: DO NOT BLEED AIR FROM THE FUEL SYSTEM OF A HOT ENGINE. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Maintenance > Filters > Fuel Filter > Component Information > Service and Repair > Fuel Filter/Water Separator Replacement > Page 1481 Fuel Supply Line Banjo Bolt 1. Loosen, but do not remove, banjo bolt holding low-pressure fuel supply line to side of fuel injection pump. Place a shop towel around banjo fitting to catch excess fuel. The fuel transfer (lift) pump is self-priming: When the key is first turned on (without cranking engine), the pump operates for approximately 2 seconds and then shuts off. The pump will also operate for up to 25 seconds after the starter is engaged, and then disengaged and the engine is not running. The pump shuts off immediately if the key is on and the engine stops running. 2. Turn key to CRANK position and quickly release key to ON position before engine starts. This will operate fuel transfer pump for approximately 25 seconds. 3. If fuel is not present at fuel supply line after 25 seconds, turn key OFF. Repeat previous step until fuel is exiting at fuel supply line. 4. tighten banjo bolt at fuel supply line to 24 Nm (18 ft. lbs.) torque. Primary air bleeding is now completed. 5. Attempt to start engine. If engine will not start, proceed to following steps. If engine does start, it may run erratically and be very noisy for a few minutes. This is a normal condition. 6. Continue to next step if: - The vehicle fuel tank has been allowed to run empty - The fuel injection pump has been replaced - High-pressure fuel lines have been replaced - Vehicle has not been operated after an extended period CAUTION: Do not engage the starter motor for more than 30 seconds at a time. Allow two minutes between cranking intervals. 7. Perform previous air bleeding procedure steps using fuel transfer pump. Be sure fuel is present at fuel supply line before proceeding. 8. Crank the engine for 30 seconds at a time to allow air trapped in the injection pump to vent out the drain manifold. WARNING: THE FUEL INJECTION PUMP SUPPLIES EXTREMELY HIGH FUEL PRESSURE TO EACH INDIVIDUAL INJECTOR THROUGH THE HIGH-PRESSURE LINES. FUEL UNDER THIS AMOUNT OF PRESSURE CAN PENETRATE THE SKIN AND CAUSE PERSONAL INJURY. WEAR SAFETY GOGGLES AND ADEQUATE PROTECTIVE CLOTHING AND AVOID CONTACT WITH FUEL SPRAY WHEN BLEEDING HIGH-PRESSURE FUEL LINES. ENGINE MAY START WHILE CRANKING STARTER MOTOR. 9. Engine may start, may run erratically and be very noisy for a few minutes. This is a normal condition. 10. Thoroughly clean area around injector fittings where they join injector connector tubes. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Maintenance > Filters > Fuel Filter > Component Information > Service and Repair > Fuel Filter/Water Separator Replacement > Page 1482 Bleeding High-Pressure Fuel Lines At Injectors 11. Bleed air by loosening high-pressure fuel line fittings at cylinders number 3, 4 and 5. 12. Continue bleeding injectors until engine runs smoothly. It may take a few minutes for engine to run smooth. 13. Tighten fuel line(s) at injector(s) to 38 Nm (28 ft. lbs.) torque. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Maintenance > Filters > Fuel Filter > Component Information > Service and Repair > Fuel Filter/Water Separator Replacement > Page 1483 Fuel Filter: Service and Repair Fuel Tank Module Replacement REMOVAL 1. Drain and remove fuel tank. Refer to Fuel Tank Removal/Installation. 2. Thoroughly clean area around tank module at top of tank. Locknut Removal/Installation - Typical Module 3. The plastic fuel tank module locknut is threaded onto fuel tank. Install Special Tool 6856 to locknut and remove locknut. The fuel tank module will spring up when locknut is removed. 4. Remove module from fuel tank. INSTALLATION CAUTION: Whenever the fuel tank module is serviced, the rubber gasket must be replaced. 1. Thoroughly clean locknut and locknut threads at top of tank. 2. Using new gasket, carefully position fuel tank module into opening in fuel tank. 3. Position locknut over top of fuel tank module. Install locknut finger tight. 4. When looking down at tank from drivers side of tank, the arrow at top of module should be aligned between two marks stamped into tank (approximately 2 o'clock position). The fuel line connectors, roll over valve and fuel gauge electrical connector should all be pointed to drivers side of vehicle. Rotate and align module/tank marks if necessary before tightening locknut. This step must be performed to prevent the module's float from contacting side of fuel tank. 5. Tighten locknut to 24-44 Nm (18-32 ft. lbs.) torque. 6. Install fuel tank. Refer to Fuel Tank Removal/ Installation. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Technical Service Bulletins > Engine - Some Oil Filters May Cause Damage Oil Filter: Technical Service Bulletins Engine - Some Oil Filters May Cause Damage NUMBER: 09-004-01 GROUP: Engine DATE: May 18,2001 SUBJECT: Engine Lubrication MODELS: 1989 - 1993 (AD) Ram Truck 1994 - 2001 (BR/BE) Ram Truck NOTE: THIS BULLETIN INVOLVES 1989-2001 MY 2500 AND 3500 RAM TRUCKS EQUIPPED WITH THE 5.9L CUMMINS DIESEL ENGINE. DISCUSSION: Customer may complain of high oil consumption, grey oil smoke coming out of the exhaust or breather tube, or mechanical knocking. Neoprene compounds used internally in the manufacture of oil filters not recommended by DaimlerChrysler may separate from the filter, lodge in the piston cooling nozzle, and can fail the engine. NOTE: THIS IS NOT AN ENGINE DEFECT. (See the table for a list of oil filters recommended by DaimlerChrysler for use with the 5.9L Cummins diesel engine.) NOTE: SECTION 2.7 OF THE TRUCK WARRANTY MANUAL STATES "DAIMLERCHRYSLER MOTORS CORPORATION IS NOT RESPONSIBLE FOR FAILURES RESULTING FROM IMPROPER REPAIR OR THE USE OF PARTS WHICH ARE NOT GENUINE DAIMLERCHRYSLER MOTORS CORPORATION / MOPAR OR DIAMLERCHRYSLER MOTORS CORPORATION / MOPAR APPROVED PARTS." DAMAGES CAUSED BY THE USE OF OIL FILTERS NOT APPROVED BY DAIMLERCHRYSLER MAY NOT BE COVERED BY THE NEW VEHICLE WARRANTY. DAIMLERCHRYSLER RECOMMENDS THE FOLLOWING OIL FILTERS. DO NOT USE ANY OIL FILTER CONTAINING NEOPRENE. PLEASE SHARE THIS WITH YOUR CUSTOMERS. RECOMMENDED OIL FILTERS FOR USE WITH CUMMINS 5.9L DIESEL ENGINE: POLICY: Information Only Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Specifications > Mechanical Specifications Oil Filter: Mechanical Specifications Oil Filter Gasket 3/4 Turn After Gasket Contact Oil Pan Bolts 18 ft.lb Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Specifications > Mechanical Specifications > Page 1490 Oil Filter: Pressure, Vacuum and Temperature Specifications Difference Pressure to Open Filter Bypass 25 psi Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Specifications > Page 1491 Oil Filter: Service and Repair All Dodge Ram engines are equipped with a high quality full-flow, disposable type oil filter. Chrysler Corporation recommends a Mopar(R), or equivalent, oil filter be used. OIL FILTER REMOVAL 1. Position a drain pan under the oil filter. 2. Using a suitable oil filter wrench, loosen filter. Oil Filter Removal-Typical 3. Rotate the oil filter counterclockwise to remove it from the cylinder block oil filter boss. 4. When filter separates from adapter nipple, tip gasket end upward to minimize oil spill. Remove filter from vehicle. Oil Filter Sealing Surface-Typical 5. With a wiping cloth, clean the gasket sealing surface of oil and grime. OIL FILTER INSTALLATION 1. Lightly lubricate oil filter gasket with engine oil or chassis grease. 2. Thread filter onto adapter nipple. When gasket makes contact with sealing surface, hand tighten filter one full turn, do not over tighten. 3. Add oil, verify crankcase oil level, and start engine. Inspect for oil leaks. USED ENGINE OIL DISPOSAL Care should be exercised when disposing of used engine oil after it has been drained from a vehicle's engine. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Technical Service Bulletins > Customer Interest for Coolant Line/Hose: > 09-04-99 > Jul > 99 > Engine Coolant Hose - Whistle/Squeal/Howl Noise Coolant Line/Hose: Customer Interest Engine Coolant Hose - Whistle/Squeal/Howl Noise NUMBER: 09-04-99 GROUP: Engine DATE: Jul. 16, 1999 SUBJECT: Hard To Diagnose Noise Coming From The Engine Turbocharger Area OVERVIEW: This bulletin involves replacement of the engine heater coolant supply hose connector. MODELS: 1998 - 1999 (BR/BE) Ram Truck NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A CUMMINS 5.9L - 24V DIESEL ENGINE BUILT PRIOR TO ENGINE SERIAL NUMBER (ESN) 56587424. THE ESN IS LOCATED ON THE ENGINE DATA PLATE WHICH IS LOCATED ON THE FRONT LEFT SIDE OF THE ENGINE, AFFIXED TO THE GEAR HOUSING. SYMPTOM/CONDITION: A noise may be present which on initial investigation may sound like a noisy turbocharger bearing. The sound of the noise may be described as a whistle, a squeal, a howl, a moan, or a gurgle. The noise will be more noticeable as engine is operated between 1,500 and 2,200 engine rpm's. The noise is usually heard in the cab, louder on the passenger side or seems to come from the dash vents. The noise may be caused by the coolant supply hose connector. The connector is located on the cylinder head next to the turbocharger. The connector is used to supply coolant to the heater hose. DIAGNOSIS: 1). Set the parking brake. Place the transmission in the park or neutral position. 2). Start engine and achieve operating temperature until the thermostat is open. 3). Increase the engine speed until the noise is heard (1,500 to 2,200 rpm). You may need to sit inside the vehicle to hear the noise. 4). With the noise present, clamp off the heater hose to prevent coolant from flowing through the connector. 5). If the noise is no longer present, then perform the Repair Procedure. 6). Stop the engine. Make certain the cooling system has cooled sufficiently to allow repair. PARTS REQUIRED: 1 05011901AC Connector, Hose AR(1) 04267020AB Antifreeze/Coolant REPAIR PROCEDURE: THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. 1. Stop the engine. Make certain the cooling system has cooled sufficiently to allow this repair. NOTE: HOT, PRESSURIZED COOLANT CAN CAUSE INJURY BY SCALDING. 2. Remove any cooling system pressure. NOTE: HOT, PRESSURIZED COOLANT CAN CAUSE INJURY BY SCALDING. USING A RAG TO COVER THE RADIATOR PRESSURE CAP, OPEN THE RADIATOR CAP SLOWLY TO THE FIRST STOP. THIS WILL ALLOW ANY BUILT-UP PRESSURE TO VENT TO THE RESERVE/OVERFLOW TANK. AFTER PRESSURE BUILD-UP HAS BEEN RELEASED, REMOVE CAP FROM THE FILLER NECK. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Technical Service Bulletins > Customer Interest for Coolant Line/Hose: > 09-04-99 > Jul > 99 > Engine Coolant Hose - Whistle/Squeal/Howl Noise > Page 1501 3. With a large clean container, drain sufficient coolant from the cooling system to prevent coolant loss when removing the heater hose. The heater hose may be clamped oft to prevent further coolant loss. 4. Remove the heater hose clamp and heater hose from the connector. 5. Replace the connector (p/n 05011901AC). Tighten the connector to 42 Nm (31 ft.lbs.). 6. Install the heater hose and hose clamp onto the connector. 7. Add engine coolant that was previously drained from the engine. 8. Start the engine. Add additional coolant as required. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 24-46-10-97 0.4 Hrs. FAILURE CODE: P8- New Part Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant Line/Hose: > 09-04-99 > Jul > 99 > Engine Coolant Hose Whistle/Squeal/Howl Noise Coolant Line/Hose: All Technical Service Bulletins Engine Coolant Hose - Whistle/Squeal/Howl Noise NUMBER: 09-04-99 GROUP: Engine DATE: Jul. 16, 1999 SUBJECT: Hard To Diagnose Noise Coming From The Engine Turbocharger Area OVERVIEW: This bulletin involves replacement of the engine heater coolant supply hose connector. MODELS: 1998 - 1999 (BR/BE) Ram Truck NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A CUMMINS 5.9L - 24V DIESEL ENGINE BUILT PRIOR TO ENGINE SERIAL NUMBER (ESN) 56587424. THE ESN IS LOCATED ON THE ENGINE DATA PLATE WHICH IS LOCATED ON THE FRONT LEFT SIDE OF THE ENGINE, AFFIXED TO THE GEAR HOUSING. SYMPTOM/CONDITION: A noise may be present which on initial investigation may sound like a noisy turbocharger bearing. The sound of the noise may be described as a whistle, a squeal, a howl, a moan, or a gurgle. The noise will be more noticeable as engine is operated between 1,500 and 2,200 engine rpm's. The noise is usually heard in the cab, louder on the passenger side or seems to come from the dash vents. The noise may be caused by the coolant supply hose connector. The connector is located on the cylinder head next to the turbocharger. The connector is used to supply coolant to the heater hose. DIAGNOSIS: 1). Set the parking brake. Place the transmission in the park or neutral position. 2). Start engine and achieve operating temperature until the thermostat is open. 3). Increase the engine speed until the noise is heard (1,500 to 2,200 rpm). You may need to sit inside the vehicle to hear the noise. 4). With the noise present, clamp off the heater hose to prevent coolant from flowing through the connector. 5). If the noise is no longer present, then perform the Repair Procedure. 6). Stop the engine. Make certain the cooling system has cooled sufficiently to allow repair. PARTS REQUIRED: 1 05011901AC Connector, Hose AR(1) 04267020AB Antifreeze/Coolant REPAIR PROCEDURE: THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. 1. Stop the engine. Make certain the cooling system has cooled sufficiently to allow this repair. NOTE: HOT, PRESSURIZED COOLANT CAN CAUSE INJURY BY SCALDING. 2. Remove any cooling system pressure. NOTE: HOT, PRESSURIZED COOLANT CAN CAUSE INJURY BY SCALDING. USING A RAG TO COVER THE RADIATOR PRESSURE CAP, OPEN THE RADIATOR CAP SLOWLY TO THE FIRST STOP. THIS WILL ALLOW ANY BUILT-UP PRESSURE TO VENT TO THE RESERVE/OVERFLOW TANK. AFTER PRESSURE BUILD-UP HAS BEEN RELEASED, REMOVE CAP FROM THE FILLER NECK. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant Line/Hose: > 09-04-99 > Jul > 99 > Engine Coolant Hose Whistle/Squeal/Howl Noise > Page 1507 3. With a large clean container, drain sufficient coolant from the cooling system to prevent coolant loss when removing the heater hose. The heater hose may be clamped oft to prevent further coolant loss. 4. Remove the heater hose clamp and heater hose from the connector. 5. Replace the connector (p/n 05011901AC). Tighten the connector to 42 Nm (31 ft.lbs.). 6. Install the heater hose and hose clamp onto the connector. 7. Add engine coolant that was previously drained from the engine. 8. Start the engine. Add additional coolant as required. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 24-46-10-97 0.4 Hrs. FAILURE CODE: P8- New Part Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Technical Service Bulletins > Page 1508 Coolant Line/Hose: Description and Operation Rubber hoses route coolant to and from the radiator, intake manifold and heater core. Radiator lower hoses are spring-reinforced to prevent collapse from water pump suction at moderate and high engine speeds. Inspect the hoses at regular intervals. Replace hoses that are cracked, feel brittle when squeezed or swell excessively when system is pressurized. The use of molded replacement hoses is recommended. When performing a hose inspection, inspect radiator lower hose for proper position and condition of spring. Hose Clamp Tool - Typical WARNING: CONSTANT TENSION HOSE CLAMPS ARE USED ON MOST COOLING SYSTEM HOSES. WHEN REMOVING OR INSTALLING, USE ONLY TOOLS DESIGNED FOR SERVICING THIS TYPE OF CLAMP, SUCH AS SPECIAL CLAMP TOOL (NUMBER 6094). SNAP-ON CLAMP TOOL (NUMBER HPC-20) MAY BE USED FOR LARGER CLAMPS. ALWAYS WEAR SAFETY GLASSES WHEN SERVICING CONSTANT TENSION CLAMPS. Clamp Number/Letter Location CAUTION: A number or letter is stamped into the tongue of constant tension clamps. If replacement is necessary, use only an original equipment clamp with a matching number or letter. Ordinary worm gear type hose clamps (when equipped) can be removed with a straight screwdriver or a hex socket. To prevent damage to hoses or clamps, the hose clamps should be tightened to 4 Nm (34 inch lbs.) torque. Do not over tighten hose clamps. For all vehicles: In areas where specific routing clamps are not provided, be sure that hoses are positioned with sufficient clearance. Check clearance from exhaust manifolds and pipe, fan blades, drive belts and sway bars. Improperly positioned hoses can be damaged, resulting in coolant loss and engine overheating. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Specifications Hose/Line HVAC: Specifications High psi control = switch opens 450 - 490 psi, resets < 270 - 330 psi = mounted on discharge line near compressor Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Locations > A/C Discharge Hose/Line Suction And Discharge Line Remove/Install Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Locations > A/C Discharge Hose/Line > Page 1514 Liquid Line Remove/Install Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Locations > A/C Discharge Hose/Line > Page 1515 Hose/Line HVAC: Locations A/C Refrigerant Hose/Line The low pressure hose (Blue with Black stripe) attaches to the suction service port located on the suction line, near the accumulator outlet. The high pressure hose (Red with Black stripe) attaches to the discharge service port located on the liquid line between the condenser and the evaporator, near the front of the engine compartment. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Locations > Page 1516 Hose/Line HVAC: Description and Operation Refrigerant Hoses/Lines/Tubes Precautions Kinks or sharp bends in the refrigerant pluming will reduce the capacity of the entire system. High pressures are produced in the system when it is operating. Extreme care must be exercised to make sure that all refrigerant system connections are pressure tight. A good rule for the flexible hose refrigerant lines is to keep the radius of all bends at least ten times the diameter of the hose. Sharp bends will reduce the flow of refrigerant. The flexible hose lines should be routed so they are at least 80 millimeters (3 inches) from the exhaust manifold. It is a good practice to inspect all flexible refrigerant system hose lines at least once a year to make sure they are in good condition and properly routed. There are two types of refrigerant fittings: All fittings with 0-rings need to be coated with refrigerant oil before installation. Use only 0-rings that are the correct size and approved for use with R-134a refrigerant. Failure to do so may result in a leak. - Unified plumbing connections with gaskets cannot be serviced with 0-rings. The gaskets are not reusable and new gaskets do not require lubrication before installing. Using the proper tools when making a refrigerant plumbing connection is very important. Improper tools or improper use of the tools can damage the refrigerant fittings. Always use two wrenches when loosening or tightening tube fittings. Use one wrench to hold one side of the connection stationary, while loosening or tightening the other side of the connection with a second wrench. The refrigerant must be recovered completely from the system before opening any fitting or connection. Open the fittings with caution, even after the refrigerant has been recovered. If any pressure is noticed as a fitting is loosened, tighten the fitting and recover the refrigerant from the system again. Do not discharge refrigerant into the atmosphere. Use an R-134a refrigerant recovery/recycling device that meets SAE Standard J2210. The refrigerant system will remain chemically stable as long as pure, moisture-free R-134a refrigerant and refrigerant oil is used. Dirt, moisture, or air can upset this chemical stability Operational troubles or serious damage can occur if foreign material is present in the refrigerant system. When it is necessary to open the refrigerant system, have everything needed to service the system ready The refrigerant system should not be left open to the atmosphere any longer than necessary. Cap or plug all lines and fittings as soon as they are opened to prevent the entrance of dirt and moisture All lines and components in parts stock should be capped or sealed until they are to be installed. All tools, including the refrigerant recycling equipment, the manifold gauge set, and test hoses should be kept clean and dry All tools and equipment must be designed for R-134a refrigerant. Refrigerant Line The refrigerant lines and hoses are used to carry the refrigerant between the various air conditioning system components. A barrier hose design with a nylon tube inner hose liner is used for the R-134a air conditioning system on this vehicle. This nylon liner helps to further contain the R-134a refrigerant, which has a smaller molecular structure than R-12 refrigerant. The ends of the refrigerant hoses are made from lightweight aluminum or steel, and use braze-less fittings. Any kinks or sharp bends in the refrigerant plumbing will reduce the capacity of the entire air conditioning system. Kinks and sharp bends reduce the flow of refrigerant in the system. A good rule for the flexible hose refrigerant lines is to keep the radius of all bends at least ten times the diameter of the hose. In addition, the flexible hose refrigerant lines should be routed so they are at least 80 millimeters (3 inches) from the exhaust manifold. High pressures are produced in the refrigerant system when the air conditioning compressor is operating. Extreme care must be exercised to make sure that each of the refrigerant system connections is pressure-tight and leak free. It is a good practice to inspect all flexible hose refrigerant lines at least once a year to make sure they are in good condition and properly routed. The refrigerant lines and hoses are coupled with other components of the HVAC system with peanut- block style fittings. A status seal type flat steel gasket with a captured compressible O-ring, is used to mate plumbing lines with A/C components to ensure the integrity of the refrigerant system. The refrigerant lines and hoses cannot be repaired and, if faulty or damaged, they must be replaced. Low Pressure Gauge Hose The low pressure hose (Blue with Black stripe) attaches to the suction service port. This port is located on the suction line, near the accumulator outlet. High Pressure Gauge Hose The high pressure hose (Red with Black stripe) attaches to the discharge service port. This port is located on the liquid line between the condenser and the evaporator, near the front of the engine compartment. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Locations > Page 1517 Recovery/Recycling/Evacuation/Charging Hose The center manifold hose (Yellow, or White, with Black stripe) is used to recover evacuate, and charge the refrigerant system. When the low or high pressure valves on the manifold gauge set are opened, the refrigerant in the system will escape through this hose. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Hose/Line Replacement Hose/Line HVAC: Service and Repair A/C Discharge Hose/Line Replacement Any kinks or sharp bends in the refrigerant plumbing will reduce the capacity of the entire air conditioning system. Kinks and sharp bends reduce the flow of refrigerant in the system. A good rule for the flexible hose refrigerant lines is to keep the radius of all bends at least ten times the diameter of the hose. In addition, the flexible hose refrigerant lines should be routed so they are at least 80 millimeters (3 inches) from the exhaust manifold. High pressures are produced in the refrigerant system when the air conditioning compressor is operating. Extreme care must be exercised to make sure that each of the refrigerant system connections is pressure-tight and leak free. It is a good practice to inspect all flexible hose refrigerant lines at least once a year to make sure they are in good condition and properly routed. WARNING: REVIEW THE WARNINGS AND CAUTIONS BEFORE PERFORMING THE FOLLOWING OPERATION. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Recover the refrigerant from the refrigerant system. Refer to: Heating and Air Conditioning, Service and Repair, Refrigerant Recovery, See: Heating and Air Conditioning/Service and Repair/Refrigerant Recovery 3. Unplug the wire harness connector from the high pressure cut-off switch. 4. Disconnect the suction line refrigerant line coupler at the accumulator. Install plugs in, or tape over all of the opened refrigerant line fittings. 5. Remove the nut that secures the block fitting to the stud on the condenser inlet and disconnect the discharge line from the condenser. Install plugs in, or tape over all of the opened refrigerant line fittings. Suction And Discharge Line Remove/Install 6. Remove the screw that secures the refrigerant line manifold to the compressor. Install plugs in, or tape over all of the opened refrigerant line fittings. 7. Remove the suction and discharge line assembly from the vehicle. INSTALLATION 1. Remove the tape or plugs from all of the refrigerant line fittings. Connect the suction line refrigerant line coupler to the accumulator. 2. Install a new gasket and the discharge line block fitting over the stud on the condenser inlet. Tighten the mounting nut to 20 Nm (180 in lbs). 3. Install the refrigerant line manifold to the compressor. Tighten the mounting screw to 22 Nm (200 in lbs). 4. Plug in the wire harness connector to the high pressure cut-off switch. 5. Connect the battery negative cable. 6. Evacuate the refrigerant system. Refer to: Heating and Air Conditioning, Service and Repair, Refrigerant System Evacuate, See: Heating and Air Conditioning/Service and Repair/Refrigerant System Evacuate 7. Charge the refrigerant system. Refer to: Heating and Air Conditioning, Service and Repair, Refrigerant System Charge, See: Heating and Air Conditioning/Service and Repair/Refrigerant System Charge Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Hose/Line Replacement > Page 1520 Hose/Line HVAC: Service and Repair A/C Liquid Hose/Line Replacement Any kinks or sharp bends in the refrigerant plumbing will reduce the capacity of the entire air conditioning system. Kinks and sharp bends reduce the flow of refrigerant in the system. High pressures are produced in the refrigerant system when the air conditioning compressor is operating. Extreme care must be exercised to make sure that each of the refrigerant system connections is pressure-tight and leak free. WARNING: REVIEW THE WARNINGS AND CAUTIONS BEFORE PERFORMING THE FOLLOWING OPERATION. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Recover the refrigerant from the refrigerant system. Refer to: Heating and Air Conditioning, Service and Repair, Refrigerant Recovery, See: Heating and Air Conditioning/Service and Repair/Refrigerant Recovery 3. Disconnect the liquid line refrigerant line couplers at the condenser outlet and the evaporator inlet. Install plugs in, or tape over all of the opened refrigerant line fittings. Liquid Line Remove/Install 4. Disengage any clips that secure the liquid line to the inner fender shield and the dash panel. 5. Remove the liquid line from the vehicle. INSTALLATION 1. Install the liquid line into any clips on the inner fender shield and the dash panel. 2. Remove the tape or plugs from the refrigerant line fittings on the liquid line, the condenser outlet, and the evaporator inlet. Connect the liquid line to the condenser and the evaporator. 3. Connect the battery negative cable. 4. Evacuate the refrigerant system. Refer to: Heating and Air Conditioning, Service and Repair, Refrigerant System Evacuate, See: Heating and Air Conditioning/Service and Repair/Refrigerant System Evacuate 5. Charge the refrigerant system. Refer to: Heating and Air Conditioning, Service and Repair, Refrigerant System Charge, See: Heating and Air Conditioning/Service and Repair/Refrigerant System Charge Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Hose/Line Replacement > Page 1521 Hose/Line HVAC: Service and Repair A/C Suction Hose/Line Replacement Any kinks or sharp bends in the refrigerant plumbing will reduce the capacity of the entire air conditioning system. Kinks and sharp bends reduce the flow of refrigerant in the system. A good rule for the flexible hose refrigerant lines is to keep the radius of all bends at least ten times the diameter of the hose. In addition, the flexible hose refrigerant lines should be routed so they are at least 80 millimeters (3 inches) from the exhaust manifold. High pressures are produced in the refrigerant system when the air conditioning compressor is operating. Extreme care must be exercised to make sure that each of the refrigerant system connections is pressure-tight and leak free. It is a good practice to inspect all flexible hose refrigerant lines at least once a year to make sure they are in good condition and properly routed. WARNING: REVIEW THE WARNINGS AND CAUTIONS BEFORE PERFORMING THE FOLLOWING OPERATION. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Recover the refrigerant from the refrigerant system. Refer to: Heating and Air Conditioning, Service and Repair, Refrigerant Recovery, See: Heating and Air Conditioning/Service and Repair/Refrigerant Recovery 3. Unplug the wire harness connector from the high pressure cut-off switch. 4. Disconnect the suction line refrigerant line coupler at the accumulator. Install plugs in, or tape over all of the opened refrigerant line fittings. 5. Remove the nut that secures the block fitting to the stud on the condenser inlet and disconnect the discharge line from the condenser. Install plugs in, or tape over all of the opened refrigerant line fittings. Suction And Discharge Line Remove/Install 6. Remove the screw that secures the refrigerant line manifold to the compressor. Install plugs in, or tape over all of the opened refrigerant line fittings. 7. Remove the suction and discharge line assembly from the vehicle. INSTALLATION 1. Remove the tape or plugs from all of the refrigerant line fittings. Connect the suction line refrigerant line coupler to the accumulator. 2. Install a new gasket and the discharge line block fitting over the stud on the condenser inlet. Tighten the mounting nut to 20 Nm (180 in lbs). 3. Install the refrigerant line manifold to the compressor. Tighten the mounting screw to 22 Nm (200 in lbs). 4. Plug in the wire harness connector to the high pressure cut-off switch. 5. Connect the battery negative cable. 6. Evacuate the refrigerant system. Refer to: Heating and Air Conditioning, Service and Repair, Refrigerant System Evacuate, See: Heating and Air Conditioning/Service and Repair/Refrigerant System Evacuate 7. Charge the refrigerant system. Refer to: Heating and Air Conditioning, Service and Repair, Refrigerant System Charge, See: Heating and Air Conditioning/Service and Repair/Refrigerant System Charge Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Line/Hose: > 19-003-02 > Apr > 02 > Power Steering - Hissing Sound Power Steering Line/Hose: Customer Interest Power Steering - Hissing Sound NUMBER: 19-003-02 GROUP: Steering DATE: April 15, 2002 SUBJECT: Hissing Sound Coming From The Power Steering System On Vehicles Equipped With Hydroboost Brakes OVERVIEW: This bulletin involves Replacing the power steering hoses connecting the Hydroboost to the power steering pump and gear. MODELS: 1997 - 2002 BR/BE Ram Truck SYMPTOM/CONDITION: A hissing sound may be present in the power steering system during steering maneuvers or straight ahead driving. DIAGNOSIS: If the vehicle exhibits the condition perform the Repair Procedure. PARTS REQUIRED REPAIR PROCEDURE: 1. Drain the power steering fluid from the system. 2. Remove the pressure hose from the power steering pump to the Hydroboost. 3. Install the new hose, p/n 05086529AA. 4. Remove the pressure hose from the Hydroboost to the steering gear. 5. Install the new hose, p/n 05086532AA. 6. Check the routing of the hoses to ensure no interference problems exist. Use tie straps to secure the hoses if necessary. 7. Fill the system with power steering fluid and operate the steering system to purge any air from the system POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE FAILURE CODE Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Line/Hose: > 19-003-02 > Apr > 02 > Power Steering Hissing Sound Power Steering Line/Hose: All Technical Service Bulletins Power Steering - Hissing Sound NUMBER: 19-003-02 GROUP: Steering DATE: April 15, 2002 SUBJECT: Hissing Sound Coming From The Power Steering System On Vehicles Equipped With Hydroboost Brakes OVERVIEW: This bulletin involves Replacing the power steering hoses connecting the Hydroboost to the power steering pump and gear. MODELS: 1997 - 2002 BR/BE Ram Truck SYMPTOM/CONDITION: A hissing sound may be present in the power steering system during steering maneuvers or straight ahead driving. DIAGNOSIS: If the vehicle exhibits the condition perform the Repair Procedure. PARTS REQUIRED REPAIR PROCEDURE: 1. Drain the power steering fluid from the system. 2. Remove the pressure hose from the power steering pump to the Hydroboost. 3. Install the new hose, p/n 05086529AA. 4. Remove the pressure hose from the Hydroboost to the steering gear. 5. Install the new hose, p/n 05086532AA. 6. Check the routing of the hoses to ensure no interference problems exist. Use tie straps to secure the hoses if necessary. 7. Fill the system with power steering fluid and operate the steering system to purge any air from the system POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE FAILURE CODE Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical Service Bulletins > Page 1535 Power Steering Line/Hose: Specifications Pressure Line ...................................................................................................................................... ...................................................... 31 Nm (23 ft. lbs.) Return Line ..................................................... .......................................................................................................................................... 31 Nm (23 ft. lbs.) Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Specifications Brake Fluid: Specifications BRAKE FLUID Specification ........................................................................................................................................ .................................................................. DOT 3 Standard .............................................................................................................................................. ........................................................... SAE J1703 NOTE: The brake fluid used in this vehicle must conform to DOT 3 specifications and SAE J1703 standards. No other type of brake fluid is recommended or approved for usage in the vehicle brake system. Use only Mopar brake fluid or an equivalent from a tightly sealed container. CAUTION: Never use reclaimed brake fluid or fluid from a container which has been left open. An open container of brake fluid will absorb moisture from the air and contaminate the fluid. CAUTION: Never use any type of a petroleum based fluid in the brake hydraulic system. Use of such type fluids will result in seal damage of the vehicle brake hydraulic system causing a failure of the vehicle brake system. Petroleum based fluids would be items such as engine oil, transmission fluid, power steering fluid, etc. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Specifications > Page 1540 Brake Fluid: Service Precautions SAFETY PRECAUTIONS WARNING: Brake fluid may be irritating to the skin or eyes. In case of contact, take the following actions: * Eye Contact-rinse eyes thoroughly with water. * Skin Contact-wash skin with soap and water. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Specifications > Page 1541 Brake Fluid: Testing and Inspection CAUTION: The hydraulic fluid used in automotive brake systems is hygroscopic. This means that the hydraulic fluid tends to absorb moisture from the atmosphere over periods of time. As hydraulic brake fluid absorbs moisture, it effects the function of the vehicles hydraulic brake system. For this reason, the vehicle's hydraulic brake fluid should be drained and replaced using fresh clean hydraulic brake fluid every two years. When replacing hydraulic brake fluid, use only Mopar brake fluid or an equivalent from a sealed container. Brake fluid must conform to DOT 3 specifications. BRAKE FLUID CONTAMINATION Indications of fluid contamination are swollen or deteriorated rubber parts. Swelling indicates the presence of petroleum in the brake fluid. To test for contamination, put a small amount of drained brake fluid in clear glass jar. If the fluid separates into layers, there is mineral oil or other fluid contamination of the brake fluid. If the brake fluid is contaminated, drain and thoroughly flush the brake system. Replace all the rubber parts or components containing rubber coming into contact with the brake fluid. This includes the master cylinder, proportioning valves, caliper seals, wheel cylinder seals, ABS hydraulic control unit (HCU), and all hydraulic fluid hoses. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Specifications > Page 1542 Brake Fluid: Service and Repair FLUID LEVEL Always clean the master cylinder reservoir and caps before checking fluid level. If not cleaned, dirt could enter the fluid. Brake Fluid Level Inspection The fluid fill level is indicated on the side of the master cylinder reservoir. The correct fluid level is to the FULL indicator on the side of the reservoir. If necessary, add fluid to the proper level. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Capacity Specifications Coolant: Capacity Specifications Cooling System Capacity .................................................................................................................... ......................................................... 24.5 L (26 qts) Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Capacity Specifications > Page 1547 Coolant: Fluid Type Specifications The required ethylene-glycol (antifreeze) and water mixture depends upon the climate and vehicle operating conditions. The recommended mixture of 50/50 ethylene-glycol and water will provide protection against freezing to -37° C (-35° F). The antifreeze concentration must always be a minimum of 44%, year round, in all climates. If percentage is lower than 44%, engine parts may be eroded by cavitation, and cooling system components may be severely damaged by corrosion. Maximum protection against freezing is provided with a 68% antifreeze concentration, which prevents freezing down to -67.7° C (-90° F). A higher percentage will freeze at a warmer temperature. Also, a higher percentage of antifreeze can cause the engine to overheat because the specific heat of antifreeze is lower than that of water. 100 Percent Ethylene-Glycol Should Not Be Used Use of 100 Percent Ethylene-Glycol will cause formation of additive deposits in the system, as the corrosive inhibitive additives in ethylene-glycol require the presence of water to dissolve. The deposits act as insulation, causing temperatures to rise as high as 149° C (300° F). this temperature is hot enough to melt plastic and soften solder. The increased temperature can result in engine detonation. In addition, 100 % ethylene-glycol freezes at 22° C (-8° F). Propylene-Glycol Formulations Should Not Be Used Propylene-glycol formulations do not meet the required specifications. It's overall effective temperature range is smaller than that of ethylene-glycol. The freeze point of 50/50 propylene-glycol and water is -32° C (-26° F), 5 degrees higher than ethylene-glycol's freeze point. The boiling point (protection against summer boil-over) of propylene-glycol is 125° C (257° F) at 96.5 kPa (14 PSI), compared to 128° C (263° F) for ethylene-glycol. Use of propylene-glycol can result in boil-over and freeze up. Propylene-Glycol also has a poorer heat transfer characteristics than ethylene-glycol. This can increase cylinder head temperatures under certain conditions. Propylene-Glycol/Ethylene-Glycol Mixtures Should Not Be Used Propylene-glycol/ethylene-glycol mixtures can cause the destabilization of various corrosion inhibitors, causing damage to the coling system components. Also, once ethylene-glycol and propylene-glycol based coolants are mixed in the vehicle, conventional methods of determining the freeze point will not be accurate. Both the refractive index and specific gravity differ between the ethylene-glycol and propylene-glycol. CAUTION: Richer antifreeze mixtures cannot be measured with normal field equipment and can cause problems associated with 100 percent ethylene-glycol. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Page 1548 Coolant: Service Precautions DO NOT mix green colored coolant with orange colored coolant. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Page 1549 Coolant: Description and Operation The cooling system is designed around the coolant. Coolant flows through the engine water jacket absorbing heat produced during engine operation. The coolant carries the heat to radiator and heater core. Here it is transferred to the ambient air passing through the radiator and heater core fins. The coolant also removes heat from the automatic transmission fluid in vehicles equipped with an automatic transmission. COOLANT PERFORMANCE ETHYLENE-GLYCOL MIXTURES The required ethyleneglycol (antifreeze) and water mixture depends upon the climate and vehicle operating conditions. The recommended mixture of 50/50 ethyleneglycol and water will provide protection against freezing to -37°C 05° F). The antifreeze concentration must always be a minimum of 44 percent, year-round in all climates. If percentage is lower than 44 percent, engine parts may be eroded by cavitation, and cooling system components may be severely damaged by corrosion. Maximum protection against freezing is provided with a 68 percent antifreeze concentration, which prevents freezing down to -67.7°C (-90°F). A higher percentage will freeze at a warmer temperature. Also, a higher percentage of antifreeze can cause the engine to overheat because the specific heat of antifreeze is lower than that of water. 100 Percent Ethyleneglycol-Should Not Be Used in Chrysler Vehicles Use of 100 percent ethyleneglycol will cause formation of additive deposits in the system, as the corrosion inhibitive additives in ethyleneglycol require the presence of water to dissolve. The deposits act as insulation, causing temperatures to rise to as high as 149°C (300)°F). This temperature is hot enough to melt plastic and soften solder. The increased temperature can result in engine detonation. In addition, 100 percent ethyleneglycol freezes at 22°C (-8°F). Propyleneglycol Formulations-Should Not Be Used in Chrysler Vehicles Propyleneglycol formulations do not meet Chrysler coolant specifications. It's overall effective temperature range is smaller than that of ethyleneglycol. The freeze point of 50/50 propyleneglycol and water is -32°C (-26°F). 5°C higher than ethyleneglycol's freeze point. The boiling point (protection against summer boil-over) of propyleneglycol is 125°C (257°F ) at 96.5 kPa (14 psi), compared to 128°C (263°F) for ethyleneglycol. Use of propyleneglycol can result in boil-over or freeze-up in Chrysler vehicles, which are designed for ethyleneglycol. Propylene glycol also has poorer heat transfer characteristics than ethylene glycol. This can increase cylinder head temperatures under certain conditions. Propyleneglycol/Ethyleneglycol Mixtures-Should Not Be Used in Chrysler Vehicles Propyleneglycol/Ethyleneglycol Mixtures can cause the destabilization of various corrosion inhibitors, causing damage to the various cooling system components. Also, once ethyleneglycol and propyleneglycol based coolants are mixed in the vehicle, conventional methods of determining freeze point will not be accurate. Both the refractive index and specific gravity differ between ethylene glycol and propylene glycol. CAUTION: Richer antifreeze mixtures cannot be measured with normal field equipment and can cause problems associated with 100 percent ethyleneglycol. COOLANT SELECTION-ADDITIVES The presence of aluminum components in the cooling system requires strict corrosion protection. Maintain coolant at specified level with a mixture of ethyleneglycol based antifreeze and water. Only use an antifreeze containing ALUGARD 340 - 2mm such as Mopar Antifreeze. If coolant becomes contaminated or looses color, drain and flush cooling system and fill with correctly mixed solution. CAUTION: Do not use coolant additives that are claimed to improve engine cooling. Dodge Ram 2500 4wd Workshop Manual (Truck L6-5.9L DSL Turbo VIN 6 (1999)) Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Page 1550 Coolant: Service and Repair Refer to Cooling System, Service and Repair for applicable service procedures.